Dodge - Durango 4wd - Workshop Manual - 1999 - 1999

Factory Workshop Manual Make Dodge Model Durango 4wd Engine and year V8-5.9L VIN Z LDC (1999) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations 8w-11-002 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 7 Power Door Lock Relay: Diagrams Relay And Fuse Box Driver Unlock Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 8 Power Door Lock Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 9 Power Door Lock Relay: Description and Operation SYSTEM DESCRIPTION The driver unlock relay is a 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The driver unlock relay is a electromechanical device that switches battery current to the left front door power lock motor when the Remote Keyless Entry (RKE) receiver within the high-line Central Timer Module (CTM) grounds the relay coil. Test the Driver Unlock Relay. The driver unlock relay is located in the relay and fuse block attached to the back of the junction block, under the left side of the instrument panel in the passenger compartment. The driver unlock relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 10 Power Door Lock Relay: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover and knee blocker from the instrument panel. Refer to Steering Column Opening Cover and Knee Blocker/Service and Repair for the procedures. Relay And Fuse Block 3. Reach through the outboard side of the steering column opening in the instrument panel to access the relay and fuse block on the back of the junction block. 4. Unplug the driver unlock relay from the relay and fuse block. 5. Install the driver unlock relay by aligning the relay terminals with the cavities in the relay and fuse block and pushing the relay firmly into place. 6. Connect the battery negative cable. 7. Test the relay operation. 8. Reverse the remaining removal procedures to complete the installation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications REAR WHEEL ANTILOCK (RWAL) BRAKES: Mounting Screws ................................................................................................................................. ................................................ 6 Nm (53 inch lbs.) FOUR WHEEL ANTILOCK BRAKES: CAB Screws ........................................................................................................................................ ................................ 4 - 4.7 Nm (36 - 42 inch lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > EBC 2 Antilock Brake Controller (EBC) 2 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > EBC 2 > Page 17 Antilock Brake Controller (EBC) 325 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Connector Plug C1 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Connector Plug C1 > Page 20 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Controller Antilock Brake (CAB) Electronic Brake Control Module: Description and Operation Controller Antilock Brake (CAB) The controller antilock brake module is used to monitor wheel speeds and modulates (control) hydraulic pressure in each brake channel. The modulated hydraulic pressure is used to prevent wheel lock up during braking. The CAB also provides a vehicle speed signal (VSS) to the powertrain control module. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Controller Antilock Brake (CAB) > Page 23 Electronic Brake Control Module: Description and Operation With Four Wheel Antilock Brakes 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. The CAB contains dual microprocessors. A logic block in each microprocessor receives identical sensor signals. These signals are processed and compared simultaneously. 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. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Controller Antilock Brake (CAB) > Page 24 Electronic Brake Control Module: Description and Operation With Rear Wheel Antilock Brakes 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. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. 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 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. 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 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System Electronic Brake Control Module: Service and Repair Four Wheel Antilock Brake System NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. REMOVAL 1. Disconnect battery negative cable. Harness Connector Locks 2. Push the harness connector locks to release the locks, then remove the connectors from the CAB. Pump Motor Connector 3. Disconnect the pump motor connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 27 Controller Mounting Screws 4. Remove screws attaching CAB to the HCU. 5. Remove the CAB. INSTALLATION 1. Place the CAB onto the HCU. NOTE: Insure the CAB seal is in position before installation. 2. Install the mounting screws and tighten to 4 - 4.7 Nm (36 - 42 inch lbs.). 3. Connect the pump motor harness. 4. Connect the harnesses to the CAB and lock the connectors. 5. Connect battery. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 28 Electronic Brake Control Module: Service and Repair Rear Wheel Antilock Brake System NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. REMOVAL RWAL Controller 1. Push the CAB harness connector lock to release the lock and remove the connector from the controller. 2. Remove the RWAL valve harness connector from the controller. 3. Remove the controller mounting screws and remove the controller from the mounting bracket. INSTALLATION 1. Position the controller on the bracket. 2. Install the mounting screws and tighten to 6 Nm (53 inch 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Component Locations Blower Motor Relay: Component Locations Power Distribution Center The blower motor relay is located in the PDC in the engine compartment. The high speed blower motor relay is located in the relay and fuse block, which is attached to the back of the junction block, under the left side of the instrument panel in the passenger compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Component Locations > Page 34 Blower Motor Relay: Connector Locations Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Component Locations > Page 35 Blower Motor Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 36 Blower Motor Relay: Description and Operation SYSTEM DESCRIPTION The blower motor relay is an International Standards Organization (ISO)-type relay. The relay is an electromechanical device that switches battery current from a fuse in the Power Distribution Center (PDC) directly to the blower motor. The relay is energized when the relay coil is provided a voltage signal by the ignition switch. This arrangement reduces the amount of battery current that must flow through the ignition switch. The blower motor relay control circuit is protected by a fuse located in the junction block. When the relay is de-energized, the blower motor receives no battery current. The blower motor relay is located in the PDC in the engine compartment. Refer to the PDC label for blower motor relay identification and location. The blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. High Speed Blower Motor Relay The front blower motor electrical circuit uses a high speed blower motor relay. The high speed blower motor relay is an International Standards Organization (ISO)-type relay. The relay is an electromechanical device that switches the blower motor to ground, bypassing the remainder of the blower motor feed circuit. The high speed blower motor relay is energized when the relay coil is provided a ground signal by the blower motor switch, and a battery feed from the ignition switch. When the relay is de-energized, the front blower motor ground feed is routed through the front blower motor switch and the blower motor resistor. The high speed blower motor relay is located in the relay and fuse block, which is attached to the back of the junction block, under the left side of the instrument panel in the passenger compartment. The high speed blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 37 Blower Motor Relay: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Relay Test Blower Motor Relay The high speed blower motor relay is located in the relay and fuse block, which is attached to the back of the junction block, under the left side of the instrument panel in the passenger compartment. Remove the high speed blower motor relay from the relay and fuse block as described 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 Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the ground side of the blower motor. There should be continuity between the ground circuit cavity of the blower motor wire harness connector and the relay and fuse block cavity for relay terminal 30 at all times. If OK, go to Step 2. If not OK, repair the open circuit to the blower motor as required. 2. The relay normally closed terminal cavity (87A) is not used for this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to ground. When the relay is energized, terminal 87 is connected to terminal 30 and provides a direct path to ground for the blower motor. There should be continuity between the relay and fuse block cavity for terminal 87 and ground at all times. If OK, go to Step 4. If not OK, repair the open circuit to ground as required. 4. The coil battery terminal cavity (86) is connected to the ignition switch. When the ignition switch is placed in the On position, fused ignition switch output is directed from a fuse in the junction block to the relay electromagnetic coil to energize the relay There should be battery voltage at the relay and fuse block 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 junction block fuse as required. 5. The coil ground terminal cavity (85) is connected to the high speed output circuit terminal of the blower motor switch. This terminal supplies the ground for the relay electromagnetic coil. There should be continuity between the relay and fuse block cavity for relay terminal 85 and the high speed output circuit terminal of the blower motor switch at all times. If not OK, repair the open circuit to the blower motor switch as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 38 Blower Motor Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for blower motor relay identification and location. 4. Unplug the blower motor relay from the PDC. 5. Install the blower motor relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations Compressor Clutch Relay: Component Locations Power Distribution Center The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 43 Compressor Clutch Relay: Connector Locations Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 44 A/C Compressor Clutch Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation > A/C Compressor Clutch Relay Description Compressor Clutch Relay: Description and Operation A/C Compressor Clutch Relay Description SYSTEM DESCRIPTION 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 electronic cycling clutch switch, the low pressure cut-off switch, and the high pressure cut-off switch. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation > A/C Compressor Clutch Relay Description > Page 47 Compressor Clutch Relay: Description and Operation A/C Compressor Clutch Relay-PCM Output Power Distribution Center (PDC) AIR CONDITIONING (A/C) CLUTCH RELAY-PCM OUTPUT The A/C relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. The Powertrain Control Module (PCM) activates the A/C compressor through the A/C clutch relay. The PCM regulates A/C compressor operation by switching the ground circuit for the A/C clutch relay on and off. When the PCM receives a request for A/C from A/C evaporator switch, it will adjust idle air control (IAC) motor position. This is done to increase idle speed. The PCM will then activate the A/C clutch through the A/C clutch relay. The PCM adjusts idle air control (IAC) stepper motor position to compensate for increased engine load from the A/C compressor. By switching the ground path for the relay on and off, the PCM is able to cycle the A/C compressor clutch. This is based on changes in engine operating conditions. If; during A/C operation, the PCM senses low idle speeds or a wide open throttle condition, it will de-energize the relay. This prevents A/C clutch engagement. The relay will remain de-energized until the idle speed increases or the wide open throttle condition exceeds 15 seconds or no longer exists. The PCM will also de-energize the relay if coolant temperature exceeds 125°C (257°F). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation > Page 48 Compressor Clutch Relay: Testing and Inspection Relay Test Compressor Clutch Relay 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 Relay Circuit Test in the Diagnosis and Testing. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation > Page 49 Compressor Clutch Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 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. 5. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service Precautions Control Module HVAC: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Specifications Audible Warning Device Control Module: Specifications CTM Mounting Bracket Screws (2) to Bracket on Outboard Side of Glove Box Opening 20 in.lb Bracket on Outboard Side of Glove Box Opening to Instrument Panel Screws (3) 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Specifications > Page 57 Central Timer Module Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 60 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 61 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 62 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 63 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 64 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 65 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 66 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 67 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 68 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 69 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 70 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 71 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 72 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 73 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 74 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 75 Audible Warning Device Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 76 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 77 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 78 Audible Warning Device Control Module: Connector Views Central Timer Module C1 Central Timer Module C2 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 79 Audible Warning Device Control Module: Electrical Diagrams Center Timer Module 8w-45-2 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 80 8w-45-3 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 81 8w-45-4 (Except Power Locks) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 82 8w-45-5 (Power Locks) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 83 8w-45-6 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 84 8w-45-7 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 85 8w-45-8 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 86 8w-45-9 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 87 8w-45-10 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 88 8w-45-11 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 89 8w-45-12 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 8w-45-13 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 8w-45-14 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 8w-45-15 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Central Timer Module System Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 94 Audible Warning Device Control Module: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 95 Audible Warning Device Control Module: Testing and Inspection 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 NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB scan tool and the proper Diagnostic Procedures. If the problem being diagnosed involves only the RKE driver unlock feature, be certain that the feature is enabled using a DRB scan tool and the proper Diagnostic Procedures. Also, if the problem being diagnosed involves only the driver side front door, see Relays in the Diagnosis and Testing to test the driver unlock relay before testing the CTM. 1. Check the fuses 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. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the procedures. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the CTM for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. Repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Probe the door lock switch output (lock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 8. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 8. Probe the door lock switch output (unlock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 9. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 9. Disconnect and isolate the battery negative cable. Reinstall the wire harness connectors to the CTM. Connect the battery negative cable. Back-probe the door lock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as either power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the Remote Keyless Entry (RKE) transmitter. If OK, go to Step 10. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 10. Back-probe the door unlock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter twice within five seconds. If OK, see Power Lock Motor in the Diagnosis and Testing. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 11. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run/start) circuit cavity of the 14-way CTM wire harness connector. On the high-line version of the CTM, repeat the check at the fused ignition switch output (run/accessory) circuit cavity of the 18-way CTM wire harness connector. If OK, replace the faulty CTM. If not OK, repair the open circuit from the CTM to the junction block as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 96 Audible Warning Device Control Module: Service and Repair Before replacing a high-line Central Timer Module (CTM), use a DRB scan tool to determine the current settings for the CTM programmable features. These settings should be duplicated in the replacement CTM using the DRB scan tool, before returning the vehicle to service. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box from the instrument panel. Refer to Glove Box - Removal in the Service and Repair for the procedures. Outboard Glove Box Opening Bracket Remove/Install 3. Remove the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Central Timer Module Remove/Install 4. Remove the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. 5. Remove the bracket on the outboard side of the glove box opening from the instrument panel through the glove box opening. 6. Move the CTM and its mounting bracket into the glove box opening far enough to access and disengage the instrument panel wire harness retainer Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 97 from the CTM mounting bracket. 7. Disconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) from the CTM connector receptacle(s). 8. Remove the CTM and mounting bracket unit from the instrument panel through the glove box opening. INSTALLATION 1. Position the CTM and mounting bracket unit in the instrument panel glove box opening. 2. Reconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) to the CTM connector receptacle(s). 3. Engage the instrument panel wire harness retainer with the hole in the CTM mounting bracket. 4. Engage the tab on the outboard end of the CTM mounting bracket in the slot in the right instrument panel end bracket. 5. Working through the instrument panel glove box opening, position the outboard glove box opening bracket to the CTM mounting bracket. 6. Install and tighten the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. Tighten the screws to 2.2 Nm (20 in. lbs.). 7. Install and tighten the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 8. Install the glove box onto the instrument panel. Refer to Glove Box - Installation/Service and Repair for the procedures. 9. Reconnect the battery negative cable. NOTE: If a new high-line Central Timer Module is installed, the programmable features must be enabled and/or disabled to the customer's preferred settings. Use a DRB scan tool and the proper Diagnostic Procedures to perform these operations. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations Daytime Running Lamp Module The Daytime Running Lamp Module is located on the left inner fender Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 102 Daytime Running Lamp Control Unit: Description and Operation GENERAL INFORMATION The headlamps on vehicles sold in Canada, will go on when the ignition is turned ON. The module must also receive a signal from the engine controller. This provides a constant Lights On condition while the vehicle is rolling. The lamps illuminate at less than 50% of normal intensity. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 103 Daytime Running Lamp Control Unit: Service and Repair The Daytime Running Lamp Module is located on the left inner fender. REMOVAL Daytime Running Lamp Module 1. Remove the bolt attaching the module to the inner fender. 2. Disconnect the electrical connector. INSTALLATION 1. Connect the electrical connector. 2. Insert the tab on the DRLM into the slot on the left inner fender. 3. Install the bolt attaching the module to the left inner fender. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 107 Fog/Driving Lamp Relay: Diagrams Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 108 Fog Lamp Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Power Distribution Center The headlamp relay is located in the Power Distribution Center (PDC), behind the battery on the left side of the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 112 Headlamp Relay: Diagrams Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 113 Headlamp Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 114 Headlamp Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 115 Headlamp Relay: Description and Operation SYSTEM DESCRIPTION The headlamp (or security) relay is a 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay The headlamp relay is a electromechanical device that switches battery current to the headlamps when the high-line Central Timer Module (CTM) grounds the relay coil. See Headlamp Relay Diagnosis and Testing for more information. The headlamp relay is located in the Power Distribution Center (PDC), behind the battery on the left side of the engine compartment. The headlamp relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 116 Headlamp Relay: Testing and Inspection The headlamp (or security) and horn relays are located in the Power Distribution Center (PDC) in the engine compartment. Each of these relays can be tested as described in the following procedure, however the circuits they are used in do vary To test the relay circuits. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. Relay Terminals 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, test the relay circuits. If not OK, replace the faulty relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 117 Headlamp Relay: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for headlamp relay identification and location. 4. Unplug the headlamp relay from the PDC. 5. Install the headlamp relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Specifications Horn Relay: Specifications Tighten the screw that secures the horn and mounting bracket unit(s) to the right front inner fender shield to 11 Nm (95 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Specifications > Page 121 Horn Relay: Locations Power Distribution Center The horn relay is located in the Power Distribution Center (PDC) in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Specifications > Page 122 Horn Relay: Diagrams Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Specifications > Page 123 Horn Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Specifications > Page 124 Horn Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Specifications > Page 125 Horn Relay: Description and Operation DESCRIPTION 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 Power Distribution Center (PDC) in the engine compartment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the PDC until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the PDC cover 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 horn relay is a 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay The horn relay is a electromechanical device that switches battery current to the horn when the horn switch or the high-line Central Timer Module (CTM) grounds the relay coil. See Horn Relay Testing and Inspection for more information. The horn relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the PDC until further diagnosis is completed. The horn relay cannot be repaired and, if faulty or damaged, it must be replaced. OPERATION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Specifications > Page 126 Horn Relay: Testing and Inspection The headlamp (or security) and horn relays are located in the Power Distribution Center (PDC) in the engine compartment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the PDC until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the PDC cover for horn relay identification and location. Each of these relays can be tested as described in the following procedure, however the circuits they are used in do vary To test the relay circuits. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. Relay Terminals Remove the relay from the PDC as described 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, test the relay circuits. 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 in the Diagnosis and Testing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Specifications > Page 127 Horn Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Distribution Center 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 horn relay identification and location. 4. Remove the horn relay from the PDC. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper horn relay location. 2. Position the horn relay in the proper receptacle in the PDC. 3. Align the horn relay terminals with the terminal cavities in the PDC receptacle. 4. Push down firmly on the horn relay until the terminals are fully seated in the terminal cavities in the PDC receptacle. 5. Install the cover onto the PDC. 6. Reconnect the battery negative cable. 8. Test the relay operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 131 Trailer Lighting Relay: Diagrams Power Distribution Center Trailer Tow Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Locations Central Timer Module: Locations Module Locations CENTRAL TIMER MODULE The Durango utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The Base CTM does not communicate on the CCD bus and will not be addressed. The CTM performs most of the typical functions a Body Control Module would perform. The module is located on the right side of the glove box behind a metal bracket. It contains a white 18-way and a green 14-way connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN WHILE IN MOTION. DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 143 Central Timer Module: 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module Central Timer Module: Description and Operation Central Timer Module DESCRIPTION Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the highline models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD 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. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. For diagnosis of the base version of the CTM, refer to Central Timer Module in the Diagnosis and Testing - Chime/Buzzer Warning Systems. For diagnosis of the high-line version of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-afterwash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermittent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. Refer to Central Timer module/Service and Repair of Instrument Panel Systems for the service procedures. See Wiper System Diagnosis and Testing for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. 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 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 Chrysler Collision Detection (CCD) 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. Refer to Remote Radio Switch in the Description and Operation for more information on this component. In addition, radio receivers connected to the CCD 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. The high-line CTM controls features and functions of the power lock, illuminated entry, and Remote Keyless Entry (RKE) systems. The high-line CTM receives hard wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio frequency inputs from the RKE transmitters. In response to those and many other inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the headlamp and horn relays, and the courtesy lamps. Some of the features and functions of the power lock, illuminated entry and RKE systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch when the driver door is open if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually, with a key, or energized with the RKE transmitter. - A programmable driver door unlock feature. The driver door unlock feature allows one press of the RKE transmitter Unlock button to unlock Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 146 just the driver door, and a second press within five seconds to unlock all doors and the liftgate. If disabled, one press of the RKE transmitter Unlock button willunlock all doors and the liftgate. - A panic mode feature which can provide additional personal security and protection. When the Panic button on the RKE transmitter is depressed the vehicle horn will pulse, the headlights will flash, and the interior lights will illuminate on the vehicle for about three minutes, or until the Panic button is depressed a second time. A vehicle speed of about 24 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. - An enhanced accident response feature will unlock all doors and the liftgate, then prevent thepower door lock system from locking the doors and liftgate for a predetermined time interval, after receiving a CCD message from the ACM indicating a frontal impact of the vehicle requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates that the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors and the liftgate after the vehicle reaches a speed of about 24 kilometers-per-hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again, at any speed above 24 kilometers-per-hour (15 miles-per-hour). - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following activation of the RKE Lock function. This feature can be enabled or disabled and, if enabled, the horn chirp duration (twenty or forty milliseconds) can be selected. - Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the service procedures. - The programmable features of the CTM can be enabled or disabled using the DRB scan tool as described in the proper Diagnostic Procedures. These features can also be enabled/disabled using the customer programmable feature. See the owner's manual in the vehicle glove box for more information on the customer programmable feature. Refer to Central Timer Module in the Diagnosis and Testing for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. - One of the features that the high-line CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard- wired inputs from the door and liftgate ajar, door and liftgate lock cylinder, and ignition switches. The programming in the CTM allows it to process the information from these inputs and send control outputs to energize or de-energize the headlamp (or security) relay, horn relay, and the security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS - The high-line CTM also contains the receiver and control logic for the power lock and Remote Keyless Entry (RKE) systems, which are integrated into the arming, disarming, and triggering functions of the VTSS. - Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the service procedures. - For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. - One of the functions and features that both versions of the CTM support is the chime warning system. The CTM contains a chime tone generator to perform the functions of the chime warning module. The CTM uses hard-wired switch inputs, internal programming, and a hard-wired chime request input from the instrument cluster circuitry to detect when a chime tone is required. This covers the diagnosis and service of only the hard-wired inputs used by the CTM to determine that a chime tone should be generated. See Central Timer Module Diagnosis and Testing for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. OPERATION Some of the functions and features that the CTM supports or controls include: Chimes for the following conditions: - Headlamps on with ignition off and driver door open warning - Key in ignition with ignition off and driver door open warning - ABS lamp warning (if the vehicle is so equipped) - Airbag lamp warning - Check gauges lamp warning - Door ajar lamp warning - Low fuel lamp warning - Low washer fluid lamp warning - Seat belt reminder lamp warning Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 147 - Transmission oil temperature lamp warning (automatic transmission) - Courtesy lamp defeat - Courtesy lamp time-out (high-line only) - Intermittent wipe control - Enhanced accident response (high-line only) - Horn chirp upon door lock with RKE (customer programmable) (high-line only) - Illuminated entry (high-line only) - Power door lock control (high-line only) - Power lock inhibit (high-line only) - Remote Keyless Entry (RKE) (high-line only) - Remote radio switches (high-line only) - Rolling door locks (customer programmable) (high-line only) - Speed sensitive intermittent wipe (high-line only) - Vehicle Theft Security System (VTSS) (high-line only) (if the vehicle is so equipped) - Wipe after wash (high-line only). More information on the operation of these CTM features and functions can be found in the system to which that feature or function applies. CENTRAL TIMER MODULE The Durango utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The Base CTM does not communicate on the CCD bus and will not be addressed. The CTM performs most of the typical functions a Body Control Module would perform. The Highline CTM provides the following features: Remote Keyless Entry (RKE) - Chime - Courtesy Lamp controls/Illuminated Entry - Power Door Locks - Speed Sensitive Intermittent Wipers - Enhanced Accident Response - Vehicle Theft Security System (VTSS) The module is located on the right side of the glove box behind a metal bracket. It contains a white 18-way and a green 14-way connector. Central Timer Module Diagnostic Trouble Codes - Door Disarm Switch Failure - Door Lock Switch Failure - Door Unlock Switch Failure - Wiper Park Switch Failure - EEPROM Checksum Failure - Internal ROM Test Failure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 148 Central Timer Module: Description and Operation DRB III Error Messages and Blank Screen DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB will display one of only two error messages: User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, recored the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key itf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III Does Not Power Up (blank Screen) 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. Perform the "DRB Blank Screen" test under Vehicle Communication. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Information Bus/DRB Blank Screen DRB III Display Is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 149 Central Timer Module: Description and Operation General Information Module Locations SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 1999 Durango consists of five modules that communicate over the CCD bus (Chrysler Collision Detection multiplex system). There are two additional modules, the Powertrain Control Module (PCM) and the Controller Anti-Lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication, The CAB also utilizes the bus for diagnostics. The PCM sends and receives messages on the CCD bus, however diagnostics are performed through the Serial Communication Interface (SCI), the same as previous years. All of the information about the functioning of all the systems is organized, controlled, and communicated by the CCD bus, which is described in Vehicle Communication. Through the CCD 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 the information to perform it's 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. 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 CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Mechanical Instrument Cluster (MIC) from the ACM via the CCD 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. Perform the WARNING LAMP CIRCUIT OPEN procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: warning lamp does not illuminate - warning lamp stays illuminated 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 150 AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. CENTRAL TIMER MODULE The Durango utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The Base CTM does not communicate on the CCD bus and will not be addressed. The CTM performs most of the typical functions a Body Control Module would perform. The Highline CTM provides the following features: Remote Keyless Entry (RKE) - Chime - Courtesy Lamp controls/Illuminated Entry - Power Door Locks - Speed Sensitive Intermittent Wipers - Enhanced Accident Response - Vehicle Theft Security System (VTSS) The module is located on the right side of the glove box behind a metal bracket. It contains a white 18-way and a green 14-way connector. Chime system The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for seat belt, gauge problems and tell-tale warnings. There are two chime rates, Low; 50 ± 12 chimes per minute for reminders and High; 180 ± 12 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 doors are open or the headlights 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 approximately 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 - Seat belt warning - Check engine lamp illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Anti-lock lamp illuminated (after prove-out if equipped) - Check gauges lamp illuminated - Low fuel warning lamp illuminated - Low washer fluid - Door ajar 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/100Km since the last reset. Instantaneous Fuel Economy Shows the fuel economy for the last few seconds in MPG or L/100Km. 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 minitrip computer displays. US/M Button Press this button to convert all vehicle displays from US to Metric to US. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 151 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, Trip Odometer, ET) is currently being displayed. 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. Enhanced Accident Response (Highline CTM Only) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the CCD bus to the CTM module to unlock the doors. The interior lights will be turned ON when the vehicle speed message on the CCD 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. Interior Lighting The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The highline CTM also provides for illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door disarm switch input or the door jamb switch input, the interior courtesy lights will be turned ON. The illuminated entry function is canceled if the CTM senses an ignition "ON" condition or the "lock" command from a valid key fob. If a door is left open or turned ON by rotation of dimmer switch for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned ON by courtesy lamp switch, the CTM will not be able to turn them OFF. The Durango utilizes an interior light defeat switch as an integral part of the headlamp switch. Mechanical Instrument Cluster (MIC) The MIC is available in 4 different versions. Two of the versions are Canadian clusters. There is a highline and a low line cluster available. The difference is the addition of a tachometer in the highline. In order to accomplish this, the fuel level gauge is reduced in size and oil pressure gauge is relocated. The cluster positions its gauges with bus messages received from the PCM. The odometer is a Liquid Crystal Display (LCD). The cluster will provide bus bias and the PCM provides termination. The MIC has an internal diagnostic routing that can be accessed by pushing and holding the trip odometer while rotating the key to the ON position. The cluster will then place all the gauges at their calibration points and will light all the CCD driven tell-tales. It will also light all the segments of the LCD display for a visual verification check. The MIC can verify communications with the PCM, ID the module, or change the country code by using options 1, 3, or 9 on the DRB III under the MIC menu. If there are faults found during the diagnostic routine, the cluster will report them on the LCD odometer display. Power Door Locks The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is OFF, the door is open, and the key is in the ignition. Automatic or "rolling locks" are included as a DRB III, or customer 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 CCD bus) indicating acceleration, the CTM will cycle the lock actuators to lock the doors. RKE/VTSS If the vehicle is equipped with Remote Keyless Entry (RKE), programming of additional transmitters and horn chirp are customer programmable features, The highline CTM provides for RKE and the Vehicle Theft Security System (VTSS). The base CTM is not able to provide these functions. The presence of either of these options dictates that the vehicle is equipped with a highline CTM. The VTSS system monitors the door ajar switches, liftgate 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, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes. After 15 minutes 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 152 DRB III. The system may be disarmed by either an unlock command from a valid RKE key fob or by using a key in the lift gate or either door. Both front door key cylinders and the lift gate 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. The RKE system is placed in the programming mode by the DRB, or by using the customer programming sequence. The system will store up to four key fob codes. Two fobs are supplied with the truck, additional fobs may be purchased through parts department. The additional fobs can be programmed with the DRB III, or by using the customer programming sequence. 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. Speed Sensitive Intermittent Wipers The DN truck equipped with a highine CTM will utilize speed sensitive intermittent wipers. Only a highine CTM Will be able to support this feature. A base CTM will provide for intermittent wipers without the speed sensitive feature. 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. Diagnostics The CTM is fully addressable with the DRB III and it is the recommended method for diagnosis. The CTM reports 6 Diagnostic Trouble Codes. All of the inputs to the CTM can be read with the DRB and the outputs can be actuated. VEHICLE COMMUNICATION The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, and is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measureable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network" located in the module that supplies bus bias or voltage. Along with the module that supplies bias, some modules provide termination. Bias is the voltage necessary to make the bus operational. At least one point of termination is necessary, some systems may use more than one. Some modules are capable of both biasing and terminating. Termination in the circuitry (a 120 ohm resistor placed across the bus) is required to complete the voltage divider network circuit and also provide some electromagnetic protection for the bus. In this vehicle, the bias is supplied by the instrument cluster and termination is provided by the PCM and the instrument cluster. Without termination, voltage on the bus goes to approximately 5 volts on one wire and 0 volts on the other wire. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB III. Problems with the operation of the bus or DRB III must corrected before proceeding with diagnostic testing. Bus Failure Messages Short to Battery - Either or both of the bus wires are shorted to the battery potential, or Open ground to any CCD bus module. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of the bus wires are shorted to ground. Bus (+) L Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with the Instrument Cluster. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 153 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. The procedure begins with AIRBAG TEST 1A-Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. 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 for 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 occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. 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 the 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, the 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. Airbag Diagnostic Trouble Codes The airbag control module may report any of the following diagnostic trouble codes. For the following codes, replace the Airbag Control Module (ACM) even if set intermittently: ACM Accelerometer - Internal Diagnostic 1 - Internal Diagnostic 2 For the following codes, replace the Airbag Control Module (ACM): ACM Output Driver - ACM Stored Energy Logic - ACM Stored Energy Driver - ACM Stored Energy Passenger - Internal Diagnostic 3 - Internal Diagnostic 4 - Safing Sensor Shorted - Warning Lamp Driver Error For these codes, refer to the appropriate diagnostic procedure: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 154 - Driver Squib Open - Driver Squib Shorted - Loss of Ignition Run Only - Loss of Ignition Run/Start - No CCD Communication - Passenger Squib Circuit Open - Passenger Squib Circuit Shorted - Either Squib Terminal Short to Battery - Either Squib Terminal Short to Ground - Warning Lamp Circuit Open - Warning Circuit Shorted Central Timer Module Diagnostic Trouble Codes - Door Disarm Switch Failure - Door Lock Switch Failure - Door Unlock Switch Failure - Wiper Park Switch Failure - EEPROM Checksum Failure - Internal ROM Test Failure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 AM/FM Switch Inoperative SYMPTOM AM-FM SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Balance Dial Inoperative SYMPTOM BALANCE DIAL INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative CD Eject Switch Inoperative SYMPTOM CD EJECT SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Equalizer Inoperative SYMPTOM EQUALIZER INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative External CD Changer (If Equipped) SYMPTOM * EXTERNAL CD CHANGER (IF EQUIPPED) POSSIBLE CAUSES - CD cable assembly defective - CD changer defective - Defective radio Fader Dial Inoperative SYMPTOM FADER DIAL INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative FF/RW Switch Inoperative SYMPTOM Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 157 FF/RW SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Hour/Minute Switch Inoperative SYMPTOM HOUR/MINUTE SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative No Sound From All Speakers SYMPTOM * NO SOUND FROM ALL SPEAKERS POSSIBLE CAUSES - Radio 12 V output circuit defective - Radio defective - Radio defective - Fused B(+) circuit open - Ground circuit open - Defective radio No Sound From One Speaker SYMPTOM * NO SOUND FROM ONE SPEAKER POSSIBLE CAUSES - Pillar speaker (+) circuit open - Pillar speaker (-) circuit open - Pillar speaker defective - Speaker (-) circuit shorted - Speaker defective - Amplifier speaker (+) circuit open - Amplifier speaker (-) circuit open - Power amplifier defective - Power amplifier defective Pause/Play Switch Inoperative SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Poor Sound Quality All Speakers SYMPTOM * POOR SOUND QUALITY ALL SPEAKERS POSSIBLE CAUSES - Antenna connector connection defective - Radio 12 V output circuit defective - Radio connections defective - Radio defective Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 158 - Radio defective - Fused B(+) circuit open - Ground circuit open - Radio choke relay connection defective Poor Sound Quality From One Speaker SYMPTOM * POOR SOUND QUALITY FROM ONE SPEAKER POSSIBLE CAUSES - Pillar/lower speaker (+) circuit open - Pillar lower speaker (-) circuit open - Pillar speaker defective - Radio defective - Radio defective - Speaker (+) circuit open - Speaker (-) circuit open - Speaker defective PWR Switch Inoperative SYMPTOM PWR SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Remote Steering Wheel Switches (If Equipped) SYMPTOM * REMOTE STEERING WHEEL SWITCHES (IF EQUIPPED) POSSIBLE CAUSES - MUX control clockspring defective - Radio control circuit defective open - Radio control switch ground circuit open - Radio MUX control circuit defective - Remote control switch defective - No response CCD bus failure - Radio control MUX circuit open - Central timer module defective Scan Switch Inoperative SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Seek Switch Inoperative SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 159 Set Switch Inoperative SYMPTOM SET SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Shorted Front Channel SYMPTOM SHORTED FRONT CHANNEL POSSIBLE CAUSES - Radio defective - Right front SPKR (+) circuit short to ground - Right front SPKR (-) circuit short to ground - Left front SPKR (+) circuit short to ground - Left front SPKR (-) circuit short to ground Shorted Left Channel SYMPTOM SHORTED LEFT CHANNEL POSSIBLE CAUSES - Left rear SPKR (+) circuit short to ground - Left rear SPKR (-) circuit short to ground - Left front SPKR (+) circuit short to ground - Left front SPKR (-) circuit short to ground - Radio defective Shorted Rear Channel SYMPTOM SHORTED REAR CHANNEL POSSIBLE CAUSES - Left rear SPKR (+) circuit short to ground - Left rear SPKR (-) circuit short to ground - Radio defective - Right rear SPKR (+) circuit short to ground - Right rear SPKR (-) circuit short to ground Shorted Right Channel SYMPTOM SHORTED RIGHT CHANNEL POSSIBLE CAUSES - Right rear SPKR (+) circuit short to ground - Right rear SPKR (-) circuit short to ground - Right front SPKR (+) circuit short to ground - Radio defective - Right front SPKR (-) circuit short to ground Tape Eject Switch Inoperative SYMPTOM TAPE EJECT SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 160 Tune Switch Inoperative SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Volume/Time Switch Inoperative SYMPTOM VOL/TIME SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative 1-5 Presets Inoperative SYMPTOM 1-5 PRESETS INOPERATIVE POSSIBLE CAUSES - Radio function controls inoperative Chime Inoperative - Engine Temperature Critical SYMPTOM * CHIME INOPERATIVE - ENGINE TEMPERATURE CRITICAL POSSIBLE CAUSES - Tone request circuit open - Instrument cluster tone request output defective - CTM fails chime test - PCM DTC - coolant temp check Chime Inoperative - Key In Ignition & LF Door Open SYMPTOM * CHIME INOPERATIVE - KEY IN IGNITION & LF DOOR OPEN POSSIBLE CAUSES - Key in ignition SW sense CKT open - Ignition SW-key in SW open - CTM no chime to key in ignition - CTM not responding to key in SW Chime Inoperative at All Times SYMPTOM * CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM fails internal chime test Chime Inoperative With Exterior Lamps On SYMPTOM * CHIME INOPERATIVE WITH EXTERIOR LAMPS ON POSSIBLE CAUSES - Headlamp switch circuit open Chime Inoperative With Low Oil Pressure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 161 SYMPTOM * CHIME INOPERATIVE WITH LOW OIL PRESSURE POSSIBLE CAUSES - Oil pressure sender ground circuit open - Tone request circuit open - Instrument cluster - oil press defective - CTM no response to oil pressure default - CTM fails chime test Chime Sounds With Driver Door Open SYMPTOM * CHIME SOUNDS WITH DRIVER DOOR OPEN POSSIBLE CAUSES - Key in ignition switch sense circuit short to ground - Ignition SW - key in SW shorted - CTM - key in sense short default - CTM not responding to key out Open Driver Door Ajar Circuit SYMPTOM * OPEN DRIVER DOOR AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Left front ajar switch sense circuit open - Left front door ajar switch defective shorted - Left front door ajar switch sense circuit open Open Gate Ajar Circuit SYMPTOM * OPEN GATE AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Liftgate ajar switch sense circuit defective open - Liftgate door ajar ground circuit defective open - Liftgate door ajar switch defective open Open Left Rear Door Ajar Circuit SYMPTOM * OPEN LEFT REAR DOOR AJAR CIRCUIT POSSIBLE CAUSES - Left rear door ajar switch sense circuit defective open - CTM defective - Ground circuit defective open - Left rear door ajar switch defective open Open Right Front Door Ajar Circuit SYMPTOM * OPEN RIGHT FRONT DOOR AJAR CIRCUIT POSSIBLE CAUSES - RF door ajar switch sense (ground circuit) open - Right front door ajar switch sense circuit open - CTM defective - Right front door ajar switch defective open Open Right Rear Door Ajar Circuit SYMPTOM * OPEN RIGHT REAR DOOR AJAR CIRCUIT Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 162 POSSIBLE CAUSES - Right rear door ajar switch sense circuit defective open - CTM defective - Ground circuit defective open - Right rear door ajar switch defective open Shorted Driver Door Ajar Circuit SYMPTOM * SHORTED DRIVER DOOR AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Left front door ajar switch defective shorted - LF door ajar switch sense circuit short to GND Shorted Gate Ajar Circuit SYMPTOM * SHORTED GATE AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Liftgate ajar switch defective shorted - Liftgate ajar switch sense circuit defective short to GND Shorted Passenger Door Ajar Circuit SYMPTOM * SHORTED PASSENGER DOOR AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Door ajar switch sense circuit short to ground - Right front door ajar switch defective shorted - Right rear door ajar switch DEF shorted - Left rear door ajar switch DEF shorted All Gauges Inoperative SYMPTOM * ALL GAUGES INOPERATIVE POSSIBLE CAUSES - No response/CCD bus (MIC) - Fuse #17 open - Fused ignition switch output circuit open - Instrument cluster defective Any CCD Cluster Warning Lamp Inoperative SYMPTOM * ANY CCD CLUSTER LAMP INOPERATIVE POSSIBLE CAUSES - No response/CCD bus (MIC) - CCD inoperative lamp/bulb defective - CCD lamp cluster input defective - Defective cluster - CCD LP cluster test complete Any Hard Wired Cluster Warning Lamp SYMPTOM * ANY HARD WIRED LAMP INOPERATIVE POSSIBLE CAUSES - Hard wired lamp circuit open Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 163 - Inoperative lamp/bulb defective - Defective instrument cluster One Gauge Not Operating Properly SYMPTOM * ONE GAUGE NOT OPERATING PROPERLY POSSIBLE CAUSES - Gauge not reading 4 PSI> engine warm at idle - Oil gauge not reading 4 PSI Or > at idle - Oil level low - Instrument cluster circuit board defective - Oil pressure sensor defective - Instrument cluster defective - Oil pressure sense circuit open - Oil pressure sense signal CKT short to ground - Cooling system operation faulty - DRB shows ECT sensor voltage too high - DRB shows ECT sensor voltage too low - Check for PCM DTC'S - Defective JTEC module - Fuel gauge inoperative - JTEC module defective - Oil pressure switch defective - Pinion factor incorrect - Powertrain control module defective - Tachometer inoperative - Voltage gauge inoperative Average MPH/Fuel Econ Inoperative or Wrong SYMPTOM * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG POSSIBLE CAUSES - Defective compass/mini-trip computer CMTC Display Shows Failed SYMPTOM * CMTC DISPLAY SHOWS FAILED POSSIBLE CAUSES - Defective CMTC display failed CMTC Fails to Respond to Instrument Panel Dimming SYMPTOM * CMTC FAILS TO RESPOND TO INSTRUMENT PANEL DIMMING TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer CMTC Segments Fail to Light Up SYMPTOM * CMTC SEGMENTS FAIL TO LIGHT UP POSSIBLE CAUSES - Defective compass mini-trip computer-segments fail to light Distance to Empty Inoperative or Wrong SYMPTOM * DISTANCE TO EMPTY INOPERATIVE OR WRONG Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 164 TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer Elapsed Time Inoperative/Wrong SYMPTOM * ELAPSED TIME INOPERATIVE/WRONG TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer Repairing OC In CMTC Display SYMPTOM * REPAIRING "OC" IN CMTC DISPLAY POSSIBLE CAUSES - Open sensor ground circuit - Defective ambient temperature sensor-SC - Open ambient temperature sensor signal circuit - Defective CMTM/OC default Repairing SC In CMTC Display SYMPTOM * REPAIRING "OC" IN CMTC DISPLAY POSSIBLE CAUSES - Ambient temperature sensor signal CKT-SH/sensor GND - Defective ambient temperature sensor-OC - Ambient temperature sensor signal CKT-short/GND - Defective CMTM/SC default Switch on Compass Mini-Trip Computer Inoperative SYMPTOM * SWITCH ON COMPASS MINI-TRIP COMPUTER INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer Trip Odometer Inoperative/Wrong SYMPTOM * TRIP ODOMETER INOPERATIVE/WRONG TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer Automatic (Rolling) Door Locks Inoperative SYMPTOM * AUTOMATIC (ROLLING) DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Link to body communication bus inoperative Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 165 - Speed sensing door locks inoperative Doors Lock With Key In Ignition and Left Door Open SYMPTOM * DOORS LOCK WITH KEY IN IGNITION AND LEFT DOOR OPEN POSSIBLE CAUSES - Link to body communication bus inoperative - Ignition switch shorted - Key-in ignition switch sense circuit open - CTM input A9 short to ground - CTM input shorted to ground One or All Doors Failing to Lock From One Switch SYMPTOM * ONE OR ALL DOORS FAILING TO LOCK FROM ONE SWITCH POSSIBLE CAUSES - Link to body communication bus inoperative - Door lock actuator assembly defective - Door unlock actuator assembly defective - Door lock switch assembly open - Door unlock switch assembly open - Door lock driver circuit open - Fused B (+) circuit open - Door lock driver circuit open - Power door lock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - CTM lock driver input open - CTM unlock driver input open - Lock driver circuit on CTM open - Unlock driver circuit on CTM open One or All Doors Failing to Unlock From One Switch SYMPTOM * ONE OR ALL DOORS FAILING TO UNLOCK FROM ONE SWITCH TEST NOTE: This symptom is diagnosed using the test * ONE OR ALL DOORS FAILING TO LOCK FROM ONE SWITCH. POSSIBLE CAUSES - Link to body communication bus inoperative - Door lock actuator assembly defective - Door unlock actuator assembly defective - Door lock switch assembly open - Door unlock switch assembly open - Door lock driver circuit open - Fused B (+) circuit open - Door lock driver circuit open - Power door lock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - CTM lock driver input open - CTM unlock driver input open - Lock driver circuit on CTM open - Unlock driver circuit on CTM open Remote Keyless Entry Problem SYMPTOM * REMOTE KEYLESS ENTRY PROBLEM POSSIBLE CAUSES - Link to body communication bus inoperative Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 166 - Transmitter defective - Circuit between CTM & left front UNLCK RLY open - Door unlock relay defective - Door unlock relay internal defect - Left front door unlock relay coil out of tolerance - Left front door unlock relay B (+) circuit open - Unlock relay B (+) circuit open (CAV 87) - CTM defective-RKE function - CTM unlock relay signal inoperative - Left front door unlock relay circuit at CTM open Intermittent Wipers Inoperative SYMPTOM * INTERMITTENT WIPERS INOPERATIVE POSSIBLE CAUSES - No response/CCD bus failure - CTM - Open intermittent wiper mode sense CKT - Open wiper park switch sense CKT - Defective wiper motor/12 volts - Defective CTM/12 volt default - Defective CTM/STALK switch - Defective multi-function switch/5.0 ohms No Wipe After Washers Actuated SYMPTOM * NO WIPE AFTER WASHERS ACTUATED POSSIBLE CAUSES - CCD bus failure-no response CTM - Open front washer switch sensor CKT - Defective CTM/washer pump Wiper Speed Sensitive Feature Inoperative SYMPTOM * WIPER SPEED SENSITIVE FEATURE INOPERATIVE POSSIBLE CAUSES - CCD bus failure-CTM - CCD bus failure PCM - Defective CTM/wiper intervals Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 167 Central Timer Module: Component Tests and General Diagnostics 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 SCREEN WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 168 Central Timer Module: Scan Tool Testing and Procedures Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, recored the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key itf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III Does Not Power Up (blank Screen) 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. Perform the "DRB Blank Screen" test under Vehicle Communication. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Information Bus/DRB Blank Screen DRB III Display Is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 169 Central Timer Module: Tools and Equipment DRB III (Diagnostic Read Out Box) Jumper Wires Ohmmeter Voltmeter Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Specifications Powertrain Control Module: Specifications Powertrain Control Module Mounting Screws 1 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Specifications > Page 173 Powertrain Control Module: Locations PCM Location And Mounting Powertrain Control Module The PCM is located in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 176 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 177 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 178 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 179 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 180 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 181 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 182 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 183 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 184 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 185 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 186 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 187 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 188 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 189 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 190 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 191 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 192 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 193 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 194 Powertrain Control Module: Connector Views Powertrain Control Module C1 Powertrain Control Module C2 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 195 Powertrain Control Module C3 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 196 Powertrain Control Module: Service and Repair PCM Location And Mounting The PCM is located in the engine compartment. REMOVAL 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 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. IMPORTANT NOTE: If the Powertrain Control Module has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the ABS and Air bag modules. In addition, if the vehicle is equipped with a Sentry Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. FOR ABS AND AIR BAG SYSTEMS: 1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS and Air Bag modules. FOR SKIM THEFT ALARM: 1. Connect the DRBIII to the data link connector. 2. Go to Theft Alarm, SKIM, Misc. and place the SKIM in secured access mode, by using the appropriate PIN code for this vehicle. 3. Select Update the Secret Key data, data will be transferred from the SKIM to the PCM (This is required to allow the vehicle to start with the new PCM). 4. If three attempts are made to enter secured access mode using the incorrect PIN, secured access mode will be locked out for one hour. To exit this lock out mode, leave the ignition key in the Run/Start position for one hour. Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Power Distributor Center (PDC) Location Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 200 Power Distribution Center The ASD relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 201 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down (ASD) Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 202 Automatic Shut Down (ASD) Relay: Description and Operation AUTOMATIC SHUTDOWN (ASD) RELAY SENSE-PCM INPUT Power Distribution Center(PDC) A 12 volt signal at this input indicates to the Powertrain Control Module (PCM) that the ASD has been activated. The ASD relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. 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 PCM does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). AUTO SHUTDOWN (ASD) RELAY-PCM OUTPUT The ASD relay is located in the Power Distribution Center (PDC). The ASD supplies battery voltage to the fuel injectors, ignition coil and oxygen (O2S) sensor heating elements. The ground circuit for the coil in the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the relay by switching the ground circuit on and off. AUTOMATIC SHUTDOWN (ASD) RELAY As one of its functions, the ASD relay will supply battery voltage to the ignition coil. The ground circuit for the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM regulates ASD relay operation by switching the ground circuit on-and-off. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 203 Automatic Shut Down (ASD) Relay: Testing and Inspection ASD And Fuel Pump Relay Terminals 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. Operation 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. Testing The following procedure applies to the ASD and fuel pump relays. 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 ± 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 source5 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 204 Automatic Shut Down (ASD) Relay: Service and Repair Power Distributor Center (PDC) Location The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. REMOVAL 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 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Distributor Center (PDC) Location Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 209 Power Distribution Center The fuel pump relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 210 Fuel Pump Relay: Diagrams Power Distribution Center Fuel Pump Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 211 Fuel Pump Relay: Description and Operation FUEL PUMP RELAY-PCM OUTPUT The PCM energizes the electric fuel pump through the fuel pump relay. Battery voltage is applied to the fuel pump relay when the ignition key is ON. The relay is energized when a ground signal is provided by the PCM. The fuel pump will operate for approximately one second unless the engine is operating or the starter motor is engaged. The fuel pump relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 212 Fuel Pump Relay: Testing and Inspection ASD And Fuel Pump Relay Terminals 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. Operation 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. Testing The following procedure applies to the ASD and fuel pump relays. 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 ± 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 source5 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 213 Fuel Pump Relay: Service and Repair Power Distributor Center (PDC) Location The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. REMOVAL 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 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Power Distributor Center (PDC) Location Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 217 Power Distribution Center The ASD relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 218 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down (ASD) Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 219 Automatic Shut Down (ASD) Relay: Description and Operation AUTOMATIC SHUTDOWN (ASD) RELAY SENSE-PCM INPUT Power Distribution Center(PDC) A 12 volt signal at this input indicates to the Powertrain Control Module (PCM) that the ASD has been activated. The ASD relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. 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 PCM does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). AUTO SHUTDOWN (ASD) RELAY-PCM OUTPUT The ASD relay is located in the Power Distribution Center (PDC). The ASD supplies battery voltage to the fuel injectors, ignition coil and oxygen (O2S) sensor heating elements. The ground circuit for the coil in the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the relay by switching the ground circuit on and off. AUTOMATIC SHUTDOWN (ASD) RELAY As one of its functions, the ASD relay will supply battery voltage to the ignition coil. The ground circuit for the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM regulates ASD relay operation by switching the ground circuit on-and-off. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 220 Automatic Shut Down (ASD) Relay: Testing and Inspection ASD And Fuel Pump Relay Terminals 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. Operation 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. Testing The following procedure applies to the ASD and fuel pump relays. 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 ± 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 source5 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 221 Automatic Shut Down (ASD) Relay: Service and Repair Power Distributor Center (PDC) Location The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. REMOVAL 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 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Locations Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Locations > Page 226 Ignition Relay: Diagrams Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Locations > Page 227 Horn, Ignition (Max Cooling) & Trailer Tow Relays Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications ACM to Transmission Tunnel Bracket Mounting Screws (3) 105 in.lb Instrument Panel Wiring Harness Ground Eyelet to Transmission Tunnel Bracket Screw 30 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 232 Air Bag Control Module: Locations Airbag Control Module Remove/Install The Airbag Control Module (ACM) is secured with screws to a mount welded onto the floor panel transmission tunnel behind the instrument panel center support bracket in the passenger compartment of the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 233 Airbag Control Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 234 Air Bag Control Module: Description and Operation DESCRIPTION The Airbag Control Module (ACM) is secured with screws to a mount welded onto 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 cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. OPERATION The microprocessor in the ACM contains the airbag system logic. The airbag system logic includes On-Board Diagnostics (OBD), and the ability to communicate with the instrument cluster circuitry over the Chrysler Collision Detection (CCD) data bus to control the airbag indicator lamp. The microprocessor continuously monitors all of the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster over the CCD data bus to turn on the airbag indicator lamp. Refer to Instrument Cluster in the Instrument Panel Systems for more information on the airbag indicator lamp. One electronic impact sensor is used in this airbag system. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. 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. In addition to the electronic impact sensor, there is an electromechanical sensor within the ACM called a safing sensor. The safing sensor is a normally open series switch located in the airbag deployment circuit of the ACM. This sensor detects impact energy of a lesser magnitude than the electronic impact sensor, and must be closed in order for the airbags to deploy The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the airbags for up to one second following a battery disconnect or failure during an impact. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact, if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 235 Air Bag Control Module: Service and Repair WARNING: - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIR BAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR BAG 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 AIR-BAG 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 AIR BAG 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. REMOVAL 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 center support bracket from the instrument panel. Refer to Instrument Panel Center Support Bracket Replacement of Instrument Panel Systems for the procedures. Airbag Control Module Remove/Install 3. Remove the screw that secures the instrument panel wire harness ground eyelet to the left side of the mount that is welded onto the floor panel transmission tunnel. 4. Disconnect the instrument panel wire harness connector from the Airbag Control Module (ACM). To disconnect the instrument panel wire harness connector from the ACM: a. Slide the red Connector Position Assurance (CPA) lock on the top of the connector toward the side of the vehicle. b. Depress the connector latch tab and pull the connector straight away from the ACM connector receptacle. 5. Remove the three screws that secure the ACM to the mount that is welded onto the floor panel transmission tunnel. 6. Remove the ACM from the mount on the floor panel transmission tunnel. INSTALLATION 1. Carefully position the ACM to the mount that is welded onto the floor panel transmission tunnel. When the ACM is correctly positioned the arrow on the ACM label will be pointed forward in the vehicle. 2. Install and tighten the three screws that secure the ACM to the mount that is welded onto the floor panel transmission tunnel. Tighten the screws to 11.8 Nm (105 in. lbs.). 3. Install and tighten the screw that secures the instrument panel wire harness ground eyelet to the left side of the mount that is welded onto the floor panel transmission tunnel. Tighten the screw to 3.4 Nm (30 in. lbs.). 4. Reconnect the instrument panel wire harness connector to the ACM connector receptacle. Be certain that the connector latch and the red CPA lock are fully engaged. 5. Do not reconnect the battery negative cable at this time. Refer to Airbag System in the Diagnosis and Testing for the proper procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Center The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 240 Starter Relay: Diagrams Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 241 Engine Starter Motor Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 242 Starter Relay: Description and Operation STARTER RELAY DESCRIPTION The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when the ignition switch is turned to the Start position. The starter 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 starter relay identification and location. The starter 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 starter relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. OPERATION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 243 Starter Relay: Testing and Inspection Starter Relay The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the fuse and relay layout label affixed to the underside of the PDC cover for starter relay identification and location. 1. Remove the starter relay from the PDC. Refer to Starter Relay/Service and Repair 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 starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay It is energized when the ignition switch is held in the Start position. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position, and no voltage when the ignition switch is released to the On position. If OK, go to Step 5. If not OK, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder Diagnosis. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded through the park/neutral position switch only when the gearshift selector lever is in the Park or Neutral positions. Check for continuity to ground at the cavity for relay terminal 85. If not OK, check for an open or short circuit to the park/neutral position switch and repair, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 244 Starter Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Distribution Center 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 starter relay identification and location. 4. Remove the starter relay from the PDC. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper starter relay location. 2. Position the starter relay in the proper receptacle in the PDC. 3. Align the starter relay terminals with the terminal cavities in the PDC receptacle. 4. Push down firmly on the starter relay until the terminals are fully seated in the terminal cavities in the PDC receptacle. 5. Install the cover onto the PDC. 6. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 255 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 256 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 262 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 263 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 264 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 The Transmission Relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 268 Transmission Control System Relay: Diagrams Transmission Control Relay Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 269 Transmission Control & Wiper Relays And C106 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 270 Transmission Control System Relay: Description and Operation TRANSMISSION RELAY-PCM OUTPUT The output to this relay provides battery voltage to the overdrive (OD), torque converter clutch (TCC) and governor pressure solenoids. Once battery voltage is applied to the solenoids, they are individually activated by the PCM through OD, TCC and governor pressure outputs. The relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Power Distribution Center The intermittent wipe relay is located in the Power Distribution Center (PDC), in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 275 Wiper Relay: Diagrams Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 276 Wiper Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 277 Wiper Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN,OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 278 Wiper Relay: Description and Operation SYSTEM OPERATION The intermittent wipe relay is a 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The intermittent wipe relay is a electromechanical device that switches battery current to the windshield wiper motor or wiper motor park switch when the relay coil is grounded by the Central Timer Module (CTM) in response to inputs from the windshield wiper (multi-function) switch. See Testing and Inspection. The intermittent wipe relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. The intermittent wipe relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 279 Wiper Relay: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN,OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Relay Test Intermittent Wipe Relay The intermittent wipe relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for intermittent wipe relay identification and location. Remove the intermittent wipe relay from the PDC as described in the Service and Repair 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 Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the wiper (multi-function) switch. There should be continuity between the cavity for relay terminal 30 and the two fused ignition switch output circuit cavities of the multi-function switch wire harness connector at all times. If OK, go to Step 2. If not OK, repair the open circuit(s) to the multi-function switch as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position. There should be continuity between the cavity for relay terminal 87A and the wiper park switch sense circuit cavities of the wiper motor wire harness connector and the 14-way Central Timer Module (CTM) wire harness connector at all times. If OK, go to Step 3. If not OK, repair the open circuit(s) to the wiper motor and CTM as required. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. There should be battery voltage at the cavity for relay terminal 87 with the ignition switch in the On or Accessory positions. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the On or Accessory positions. If OK, go to Step 5. If not OK, repair the open circuit to the ignition switch as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay It is grounded by the CTM to energize the relay and cycle the wiper motor. Check for continuity between the cavity for relay terminal 85 and the intermittent wiper relay control circuit cavity of the 14-way CTM wire harness connector. There should be continuity. If OK, replace the faulty base version CTM; or, use a DRB scan tool and the proper Diagnostic Procedures for diagnosis of the high-line version CTM. If not OK, repair the open circuit to the CTM as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 280 Wiper Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC cover for intermittent wipe relay identification and location. 4. Unplug the intermittent wipe relay from the PDC. 5. Install the intermittent wipe relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams Arm/Disarm Switch: Diagrams Driver Door Arm/Disarm Switch Driver Door Arm/Disarm Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Description and Operation Door Sensor/Switch (For Alarm): Description and Operation SYSTEM 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Description and Operation > Page 289 Door Sensor/Switch (For Alarm): Service and Repair REMOVAL AND INSTALLATION The door ajar switch is integral to the door latch unit. If the door ajar switch is faulty or damaged, the entire door latch unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Lock Cylinder Switch: Locations Door Lock Cylinder Switch Remove/Install - Typical Liftgate Lock Cylinder Switch Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 293 Lock Cylinder Switch: Description and Operation SYSTEM DESCRIPTION Door Lock Cylinder Switch The door lock cylinder switches are mounted to the back of the key lock cylinder inside each front door. They are normally-open momentary switches that close to ground only when the lock cylinder is rotated to the unlock position. The door lock cylinder switches cannot be repaired and, if faulty or damaged, they must be replaced. Liftgate Lock Cylinder Switch The liftgate lock cylinder switch is mounted to the back of the key lock cylinder inside the liftgate. It is a normally-open momentary switch that closes to ground only when the lock cylinder is rotated to the unlock position. The liftgate lock cylinder switch cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 294 Lock Cylinder Switch: Service and Repair REMOVAL AND INSTALLATION Door Lock Cylinder Switch 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 far enough to access the door lock cylinder switch. 4. Disengage the door lock cylinder switch from the back of the lock cylinder. 5. Unplug the door lock cylinder switch wire harness connector. 6. Disengage the retainers that secure the door lock cylinder switch wire harness to the inner door panel. 7. Remove the door lock cylinder switch from the door. 8. Reverse the removal procedures to install. Liftgate Lock Cylinder Switch 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 disengage the switch from the back of the liftgate lock cylinder. 4. Unplug the liftgate lock cylinder switch wire harness connector. 5. Remove the liftgate lock cylinder switch from the liftgate. 6. Reverse the removal procedures to install. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations Remote Radio Switches Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 298 Remote Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 299 Remote Switch: Description and Operation DESCRIPTION A remote radio switch option is available on models equipped with the AM/FM/C D/cassette/3-band graphic equalizer (RAZ sales code) radio receiver and the high-line Central Timer Module (CTM). Refer to Central Timer Module in the Description and Operation of Instrument Panel Systems for more information on this component. 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 side is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right side is the volume control switch and has volume up, and volume down functions. 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 in the Description and Operation of Airbags and Seat Belts/Airbags for more information on this component. OPERATION 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 Chrysler Collision Detection (CCD) 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 CCD 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 300 Remote Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. 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 Chrysler Collision Detection (CCD) data bus. If not OK, repair the open radio control mux circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 301 Remote Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag module from the steering wheel. Refer to Driver Side Airbag Module Replacement of Air Bags and Seat Belts/Air Bags for the procedures. 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 Switches/Service and Repair of Speed Control System for the procedures. 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 Switches/Service and Repair of Speed Control System for the procedures. 5. Install the driver side airbag module onto the steering wheel. Refer to Driver Side Airbag Module Replacement of Air Bags and Seat Belts/Air Bags for the procedures. 6. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Description and Operation Trunk/Liftgate Sensor/Switch (For Alarm): Description and Operation SYSTEM DESCRIPTION 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Description and Operation > Page 305 Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair The liftgate ajar switch is integral to the liftgate latch unit. If the liftgate ajar switch is faulty or damaged, the entire liftgate latch unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Specifications Power Door Lock Switch: Specifications Power Lock Switch Mounting Screws 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Specifications > Page 310 Driver Power Window/Door Lock Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Specifications > Page 311 Power Door Lock Switch: Description and Operation SYSTEM OPERATION The power locks can be controlled by a two-way switch integral to the power window and lock switch unit on the driver side front door trim panel, or a two-way single gang switch on the passenger side front door trim panel. The power lock switch controls the battery feeds to the lock and unlock sense inputs of the high-line Central Timer Module (CTM). The CTM then relays the correct battery and ground feeds to the power lock motors. A Light-Emitting Diode (LED) in the paddle of each switch is illuminated whenever the ignition switch is in the On position. The driver side power window and lock switch unit cannot be repaired and, if faulty or damaged, the entire switch unit must be replaced. The passenger side power lock switch cannot be repaired and, if faulty or damaged, the switch must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Specifications > Page 312 Power Door Lock Switch: Testing and Inspection If the problem being diagnosed involves only the power lock switch illumination LEDs, check the fused ignition switch output (run) and ground circuits at the power lock switch connector. 1. Check the 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. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Unplug the wire harness connector from the power lock switch. 4. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the body half of the power lock switch wire harness connector. If OK, go to Step 5. If not OK, repair the open circuit to the junction block as required. Power Lock Switch Continuity - Driver Side Power Lock Switch Continuity - Passenger Side 5. Test the power lock switch continuity See the Power Lock Switch Continuity charts to determine if the continuity is correct in the Off, Lock and Unlock switch positions. If OK, repair the door lock switch output (lock Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Specifications > Page 313 and/or unlock) circuit(s) from the body half of the power lock switch wire harness connector to the Central Timer Module (CTM) as required. If not OK, replace the faulty switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Specifications > Page 314 Power Door Lock Switch: Service and Repair REMOVAL Driver Side Front Door 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the driver side front door. 3. From the back side of the trim panel, remove the screws that secure the power window and lock switch unit to the switch bezel in the door trim panel opening. 4. Remove the power window and lock switch and the switch bezel from the door trim panel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Passenger Side Front Door 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the passenger side front door. 3. With a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power window switch receptacle on the back of the door trim panel switch bezel and pull the switch out of the receptacle. 4. Reverse the removal procedures to install. Be certain that both of the switch snap retainers in the receptacle on the back of the door trim panel switch bezel are fully engaged. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Power Mirror Switch Knob Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 318 Power Mirror Switch: Description and Operation SYSTEM DESCRIPTION Both the right and left power outside mirrors are controlled by a single multi-function switch unit located on and mounted to the upper flag area of the driver side door trim panel. The switch knob is rotated clockwise (right mirror control), or counterclockwise (left mirror control) to select the mirror to be adjusted. The switch knob is then moved in a joystick fashion to control movement of the selected mirror up, down, right, or left. The power mirror switch cannot be repaired and, if faulty or damaged, it must be replaced. The power mirror switch knob is available for service replacement. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 319 Power Mirror Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Mirror Switch Knob Remove/Install 2. Pull the power mirror switch control knob rearward to remove it from the switch stem. Power Mirror Switch Nut 3. Remove the nut that secures the power mirror switch to the driver side door trim panel. 4. Remove the trim panel from the inside of the driver side front door. 5. Pull the trim panel away from the inner door panel far enough to access the power mirror switch wire harness connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 320 Door Trim Panel Wire Harness Connectors 6. Unplug the power mirror switch wire harness connector. 7. Remove the power mirror switch from the back of the door trim panel. 8. Reverse the removal procedures to install. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications Power Seat Switch: Specifications Power Seat Switch Mounting Screws 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications > Page 324 Power Seat Switch: Locations Power Seat Switch Remove/Install - Typical The switch is located on the lower outboard side of the seat cushion on the seat cushion side shield. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications > Page 325 Power Seat Switch: Description and Operation SYSTEM OPERATION The power seat can be adjusted in six different ways using the power seat switch. The switch is located on the lower outboard side of the seat cushion on the seat cushion side shield. Refer to the owner's manual for more information on the power seat switch functions and the seat adjusting procedures. The individual switches in the power seat switch unit cannot be repaired. If one switch is damaged or faulty, the entire power seat switch unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications > Page 326 Power Seat Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Power Seat Switch Continuity 3. Use an ohmmeter to test the continuity of the power seat switches in each position. See the Power Seat Switch Continuity chart. If OK, see Power Seat Adjuster and Motors in the Diagnosis and Testing. If not OK, replace the faulty power seat switch unit. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications > Page 327 Power Seat Switch: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the driver side front seat. 3. Pull the recliner lever off of the recliner mechanism release shaft. 4. Remove the three screws that secure the driver side seat cushion side shield to the outboard seat cushion frame. 5. Pull the driver side seat cushion side shield away from the seat cushion frame far enough to access the power seat switch module wire harness connector. 6. Unplug the wire harness connector from the power seat switch module. 7. Remove the seat cushion side shield and power seat switch module from the seat as a unit. Power Seat Switch Remove/Install - Typical 8. Remove the two screws that secure the power seat switch to the inside of the seat cushion side shield. 9. Remove the power seat switch from the seat cushion side shield. 10. Reverse the removal procedures to install. Tighten the switch mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations Brake Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 332 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 333 Brake Fluid Pressure Sensor/Switch: Testing and Inspection PRESSURE DIFFERENTIAL SWITCH 1. Have 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations Brake Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 337 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Rear Wheel Anti-Lock (RWAL) Brakes Mounting Bolt 200 in.lb Front Wheel Anti-Lock Brakes Front Sensor Bolt 190 in.lb Rear Sensor Bolt 200 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Rear Wheel Speed Sensor Tone Wheel Front Wheel Speed Sensor Rear Wheel Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 343 Wheel Speed Sensor: Connector Locations Left Front Wheel Speed Sensor Connector Right Front Wheel Speed Sensor Connector Rear Wheel Speed Sensor Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front Wheel Speed Sensor: Diagrams Front Connector Pin Identification Connector Pin Identification Connector Pin Identification Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front > Page 346 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes Wheel Speed Sensor: Description and Operation Four Wheel Antilock Brakes The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front steering knuckles. The third sensor is mounted on top of the rear axle differential housing. The sensor is a magnet coil that is mounted over a tone wheel front/exciter ring rear with an air gap between them. The sensors measure the wheel speed by monitoring the rotation of the tone wheels front/exciter ring rear. As the teeth of the tone wheels front/exciter ring rear move through the magnetic field of the sensor an AC voltage is generated. This signal frequency increases or decreases proportionally to the speed of the wheel. The CAB monitors these signals for changes in wheel deceleration. If the CAB detects a sudden wheel or wheels deceleration within a predetermined amount the CAB will activate the ABS system. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 349 Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brakes Rear Wheel Speed Sensor Location The rear Wheel Speed Sensor (WSS) is mounted in the rear differential housing. 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. Exciter Ring Location The exciter ring is press fitted onto the differential carrier next to the final drive ring gear. Operation Of The Wheel Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 350 When the ring gear is rotated, the exciter ring passes the tip of the WSS. As the exciter ring passes the tip of the WSS, the magnetic lines of force of the sensor are cut, causing the magnetic field to be moved across the sensor's windings. This, in turn causes current to flow through the WSS circuit. 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 rotates, the stronger the signal will be - Distance between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring, 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. Data Link Connector - Typical The assembly plant performs a "Rolls Test" on every vehicle that leaves the assembly plant. One of the tests 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Front CAUTION: Special bolts are used to attach the front sensor. The bolts have a special shoulder, thread length and surface treatment. If the original bolts must be replaced, use only factory replacement bolts. Do not use substitute bolt under any circumstances. REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper and rotor. Front Wheel Speed Sensor - 4X4 4. Remove bolts attaching sensor to hub/bearing. 5. Remove clamps securing sensor wire to control arm and inner fender panel. 6. In engine compartment, disconnect sensor wire and remove sensor. INSTALLATION 1. Guide sensor wire around upper control arm. 2. Position sensor on hub/bearing and install attaching bolts. Tighten bolt to 18 - 25 Nm (160 - 220 inch lbs.). 3. Secure sensor wire retaining clamps to control arm and fender panel with original hardware. 4. In engine compartment, connect sensor wire to harness connector. Insure wire is routed away from hot or rotating underhood components. 5. Install brake rotor and caliper. 6. Install wheel and tire assembly. 7. Turn steering wheel back and forth that wire is clear of steering and suspension components. 8. Remove supports and lower vehicle. With Rear Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 353 Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 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. With Four Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 354 Wheel Speed Sensor: Service and Repair Tone Wheel Replacement Front Tone Wheel Tone Wheel 4X2 The tone wheel for the front speed sensor is located on the hub/bearing on 2-wheel drive models. On 4-wheel drive models, the tone wheel is located in the hub/bearing housing. The tone wheel is not a serviceable component. To replace the tone wheel the hub/bearing must be replaced. Rear Tone Wheel The toothed exciter ring is press-fitted onto the differential carrier next to the final drive ring gear in the differential case. If the ring is damaged, refer to Transmission and Drivetrain for service procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 11 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 360 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor-Typical Intake Air Temperature Sensor, Engine Coolant Temperature Sensor Connector, Ignition Coil The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 361 Engine Coolant Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 362 Coolant Temperature Sensor/Switch (For Computer): Service Precautions WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 363 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT The engine coolant temperature sensor is installed into a water jacket at the front of the intake manifold located near the rear of the generator. The sensor provides an input voltage to the Powertrain Control Module (PCM) relating coolant temperature. The PCM uses this input along with inputs from other sensors to determine injector pulse width and ignition timing. As coolant temperature varies, the coolant temperature sensor resistance will change. This change in resistance results in a different input voltage to the PCM. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 364 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: Engine Coolant Temperature Sensor-Typical 1. Disconnect wire harness connector from coolant temperature sensor. 2. Engines with air conditioning: When removing the connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place the hook part of tool under the connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. Sensor Resistance(Ohms)-Coolant Temperature Sensor/Intake Air Temperature Sensor 3. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. The resistance (as measured across the sensor terminals) should be as shown in the SENSOR RESISTANCE (OHMS)-COOLANT TEMPERATURE SENSOR/INTAKE AIR TEMPERATURE SENSOR resistance chart. Replace the sensor if it is not within the range of resistance specified in the chart. 4. Test continuity of the wire harness between the PCM wire harness connector and the coolant sensor connector terminals. Refer to Wiring for terminal/cavity locations. Repair the wire harness if an open circuit is indicated. 5. After tests are completed, connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 365 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor-Typical The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain cooling system. 2. Disconnect electrical connector from sensor. 3. Engines with air conditioning: When removing the connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place the hook part of tool under the connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Use long needle nose pliers to connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. 4. Replace any lost engine coolant. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Brake Switch (Cruise Control): Locations The switch is mounted on the brake pedal mounting bracket under the instrument panel Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 370 Brake Switch (Cruise Control): Description and Operation DESCRIPTION The switch is mounted on the brake pedal mounting bracket under the instrument panel. OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The PCM monitors the state of the dual function stop lamp switch. Refer to the Brake for more information on stop lamp switch service and adjustment procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications Cruise Control Switch: Specifications Tighten screws to 1.5 N.m (14 in. lbs.) torque Switch Module Mounting Screws 1.5 N.m (14 in. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 374 Speed Control Switches Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Left Speed Control Switch - White 2 Way Left Speed Control Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Left Speed Control Switch - White 2 Way > Page 377 Right Speed Control Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 378 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 379 Cruise Control Switch: Description and Operation DESCRIPTION Two separate speed control switch modules are mounted on the steering wheel to the left and right side of the driver's airbag module. The two switch modules are labeled: ON/OFF, SET, RESUME/ACCEL, CANCEL and COAST. 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 individual switch fails, the switch module must be replaced. OPERATION Within the two switch modules, five momentary contact switches, supporting seven different speed control functions are used. The outputs from these switches are filtered into one input. The Powertrain Control Module (PCM) determines which output has been applied through resistive multiplexing. The input circuit voltage is measured by the PCM to determine which switch function has been selected. A speed control indicator lamp, located on the instrument panel cluster is energized by the PCM via the CCD Bus. This occurs when speed control system power has been turned ON, and the engine is running. SPEED CONTROL SWITCHES-PCM INPUT Six different speed control functions, using three momentary contact switches, are monitored through this multiplexed input. The resistance monitored at this input, in combination with the length of time the PCM measures the resistance, determines which switch feature has been selected. The three switches are: On/Off; Set/Coast, Cancel and Resume/Accelerate. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 380 Cruise Control Switch: Testing and Inspection To perform a complete test of the speed control switch circuits, refer to the appropriate Powertrain Diagnostic Procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 381 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 N.m (14 in. lbs.) torque 4. Install airbag module. Refer to Passive Restraint Systems for procedures. 5. Connect negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Description and Operation Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation The Vehicle Speed Sensor (VSS) is no longer used for any Dodge Truck. Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for speed control system operation. For the location of the transmission output shaft sensor, please refer to Transmission Speed Sensor/Locations. See: Sensors and Switches - Powertrain Management/Sensors and Switches Computers and Control Systems/Vehicle Speed Sensor/Locations For the location of the rear wheel speed sensor, please refer to Brakes and Traction Control/Brakes/Antilock Brake System/Wheel Speed Sensor/Locations. See: Sensors and Switches - Brakes and Traction Control/Wheel Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Component Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Component Locations > Page 390 Oil Pressure Sending Unit/Switch, Camshaft Position Sensor Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 391 Oil Pressure Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams Engine Oil Pressure Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 395 Oil Pressure Sensor: Description and Operation OIL PRESSURE SENSOR-PCM INPUT Sends a signal from the oil pressure sending unit to the Powertrain Control Module (PCM) relating to engine oil pressure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Ambient Temperature Sensor / Switch HVAC: Specifications Ambient Temperature Sensor Bracket to Radiator Yoke Screw 50 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 400 Ambient Temperature Sensor / Switch HVAC: Locations Ambient Temperature Sensor Remove/Install The ambient temperature sensor is mounted on the right side of the radiator yoke behind the grille. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 401 Ambient Air Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 402 Ambient Temperature Sensor / Switch HVAC: Description and Operation DESCRIPTION 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. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. OPERATION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 403 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 (231° 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. 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 kilohms. At 55° C (131° F), the sensor resistance is 2.488 kilohms. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 404 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations Blower Motor Switch: Locations Rear Blower Motor Switch Remove/Install The blower motor switch is mounted in the heater-A/C control panel Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 408 Blower Motor Switch: Description and Operation SYSTEM DESCRIPTION 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. Rear The optional rear overhead A/C unit blower motor is controlled by a four position rotary-type blower motor switch, mounted by a snap fit in a hole in the headliner over the right front seat back. The switch allows the selection of one of three blower motor speeds and an Off position. The blower motor switch directs the blower motor ground path through the blower motor resistor. The blower motor switch cannot be repaired and, if faulty or damaged, the entire switch unit must be replaced. The blower motor switch has a replaceable incandescent-type illumination lamp bulb. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 409 Blower Motor Switch: Testing and Inspection Front WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check for battery voltage at the 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. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the heater-A/C control from the instrument panel. Check for continuity between the ground circuit cavity of the heater-A/C control wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 3. With the heater-A/C control wire harness connector unplugged, place the heater-A/C mode control switch knob to any position except the Off position. Check for continuity between the ground circuit terminal and each of the blower motor driver circuit terminals of the heater-A/C control as you move the blower motor switch knob to each of the four speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the blower driver circuits between the heater-A/C control connector and the blower motor resistor as required. If not OK, replace the faulty heater-A/C control unit. Rear 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the rear blower motor switch from the headliner. Check for continuity between the ground circuit cavity of the rear blower motor switch wire harness connector and a good ground. There should be continuity If OK, go to Step 2. If not OK, repair the open circuit to ground as required. 2. With the rear blower motor switch wire harness connector unplugged, place the rear blower motor switch knob to any position except the Off position. Check for continuity between the ground circuit terminal and each of the blower motor driver circuit terminals of the rear blower motor switch as you move the blower motor switch knob to each of the three speed positions. There should be continuity at each driver circuit terminal in only one blowermotor switch speed position. If OK, test and repair the rear blower driver circuits between the rear blower motor switch wire harness connector and the blower motor resistor as required. If not OK, replace the faulty rear blower motor switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 410 Blower Motor Switch: Service and Repair The rear blower motor switch is used only on models with the optional rear overhead air conditioning unit. REMOVAL 1. Disconnect and isolate the battery negative cable. Rear Blower Motor Switch Remove/Install 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 blower motor switch 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 1. Plug the wire harness connector into the back of the rear blower motor switch. 2. Check 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations High Pressure Cut-Off Switch Remove/Install The high pressure cut-off switch is located on the discharge line near the compressor. Low Pressure Cut-Off Switch Remove/Install The low pressure cycling clutch switch is located on the side near the top of the accumulator. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 415 High Pressure Sensor / Switch: Description and Operation SYSTEM OPERATION High Pressure Cut-off Switch The high pressure cut-off switch is located on the discharge line near the compressor. The switch is screwed onto a fitting that contains a Schrader-type valve, which allows the switch to be serviced without discharging the refrigerant system. The discharge line fitting is equipped with an O-ring to seal the switch connection. The high pressure cut-off switch is connected in series electrically with the electronic cycling clutch switch and the low pressure cut-off switch 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 discharge line pressure approaches high levels. The high pressure cut-off switch contacts will open when the discharge line pressure rises above about 3100 to 3375 kPa (450 to 490 psi). The switch contacts will close when the discharge line pressure drops to about 1860 to 2275 kPa (270 to 330 psi). The high pressure cut-off switch is a factory-calibrated unit. The switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 416 High Pressure Sensor / Switch: Testing and Inspection Before performing diagnosis of the high pressure cut-off switch, verify that the refrigerant system has the correct refrigerant charge. 1. Disconnect and isolate the battery negative cable. 2. Unplug the high pressure cut-off switch wire harness connector from the switch on the refrigerant system fitting. 3. Check for continuity between the two terminals of the high pressure cut-off switch. There should be continuity. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 417 High Pressure Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. High Pressure Cut-Off Switch Remove/Install 2. Unplug the wire harness connector from the high pressure cut-off switch, which is mounted to a fitting on the discharge line between the compressor and the condenser inlet. 3. Unscrew the high pressure cut-off switch from the discharge line fitting. 4. Remove the high pressure cut-off 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 discharge 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 high pressure cut-off switch on the discharge line fitting. 3. Plug the wire harness connector into the high pressure cut-off switch. 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Electronic Cycling Clutch Switch Low Pressure Sensor / Switch: Locations Electronic Cycling Clutch Switch Low Pressure Cut-Off Switch Remove/Install The Electronic Cycling Clutch Switch (ECCS) is mounted to the outboard side of the thermal expansion valve in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Electronic Cycling Clutch Switch > Page 422 Low Pressure Sensor / Switch: Locations Low Pressure Cycling Clutch Switch High Pressure Cut-Off Switch Remove/Install The high pressure cut-off switch is located on the discharge line near the compressor. Low Pressure Cut-Off Switch Remove/Install The low pressure cycling clutch switch is located on the side near the top of the accumulator. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Electronic Cycling Clutch Switch Low Pressure Sensor / Switch: Description and Operation Electronic Cycling Clutch Switch Freeze-Up Control = Electronic Clutch Cycling Switch (ECCS) mounted on expansion valve SYSTEM DESCRIPTION Electronic Cycling Clutch Switch The Electronic Cycling Clutch Switch (ECCS) is mounted to the outboard side of the thermal expansion valve in the engine compartment. A thermistor probe within a capillary tube on the switch is inserted into a well on the side of the expansion valve filled with a thermally-conductive grease. This arrangement allows the ECCS to monitor the temperature of the expanded refrigerant entering the evaporator. The function of the ECCS is to prevent refrigerant temperatures from becoming so low that condensation freezes on the evaporator fins. This condition is referred to as evaporator icing. Evaporator icing reduces air conditioning system air flow and cooling performance. The ECCS is connected in series electrically with the heater-A/C mode control switch, the low pressure cut-off switch and the high pressure cut-off switch between ground and the Powertrain Control Module (PCM). The ECCS will open when it monitors a refrigerant temperature below about 2.9° C (37.2° F), and will close again when the refrigerant temperature reaches about 4.3° C (39.7° F). The opening and closing of the ECCS signals the PCM to cycle the compressor clutch on and off through the compressor clutch relay. The ECCS is a factory sealed and calibrated unit and cannot be adjusted or repaired. If faulty or damaged, the ECCS must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Electronic Cycling Clutch Switch > Page 425 Low Pressure Sensor / Switch: Description and Operation Low Pressure Cut-Off Switch SYSTEM OPERATION Low Pressure Cycling Clutch Switch The low pressure cycling clutch switch is located on the side near the top of the accumulator. The switch is screwed onto an accumulator fitting that contains a Schrader-type valve, which allows the switch to be serviced without discharging the refrigerant system. The accumulator fitting is equipped with an O-ring to seal the switch connection. The low pressure cycling clutch switch is connected in series electrically with the high pressure cut-off switch and 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 regulates the refrigerant system pressure and controls evaporator temperature. Controlling evaporator temperature prevents condensate water on the evaporator fins from freezing and obstructing air conditioning system air flow. The low pressure cycling clutch switch contacts will open when the suction pressure is about 141 kPa (20.5 psi) or lower. The switch contacts will close when the suction pressure rises to about 234 to 262 kPa (34 to 38 psi) or above. Lower ambient temperatures, below about -1° C (30° F), will also cause the switch contacts to open. This is due to the pressure/temperature relationship of the refrigerant in the system. The low pressure cycling clutch switch is a factory-calibrated unit. It cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Testing and Inspection > Low Pressure Cut-Off Switch Low Pressure Sensor / Switch: Testing and Inspection Low Pressure Cut-Off Switch Before performing diagnosis of the low pressure cut-off switch, remember that lower ambient temperatures, below about -1° C (30° F), 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 low pressure cut-off switch wire harness connector from the switch on the suction line jumper fitting. 3. Install a jumper wire between the two cavities of the low pressure cut-off switch wire 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 low pressure cut-off switch. There should be continuity with a suction pressure (low side) reading of 89.6 to 186.1 kPa (13 to 27 psi) or above, and no continuity with a suction pressure reading of 68.9 kPa (10 psi) or below. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Testing and Inspection > Low Pressure Cut-Off Switch > Page 428 Low Pressure Sensor / Switch: Testing and Inspection Electronic Cycling Clutch Switch (Front Unit Only) Use a volt/ohmmeter to test the electronic cycling clutch switch. Verify that the refrigerant system has the correct refrigerant charge. Check that both the low and high pressure cut-off switches are functional as described in the Diagnosis and Testing before testing the electronic cycling clutch switch. 1. Disconnect and isolate the battery negative cable. Unplug the wire harness connectors at the electronic cycling clutch switch and the high pressure cut-off switch. Check for continuity between the C90A circuit cavities in the body half of the electronic cycling clutch switch wire harness connector and the high pressure cut-off switch wire harness connector. There should be continuity If OK, go to Step 2. If not OK, repair the open circuit as required. 2. Unplug the wire harness connector at the low pressure cut-off switch. Check for continuity between the C2 circuit cavities in the body half of the electronic cycling clutch switch wire harness connector and the low pressure cut-off switch wire harness connector. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit as required. 3. Plug in the wire harness connectors at the low pressure cut-off and high pressure cut-off switches. Connect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (RUN) circuit cavity in the body half of the electronic cycling clutch switch wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit to the junction block as required. 4. Plug in the wire harness connector at the electronic cycling clutch switch. With the ambient temperature from 20 - 30 °C (68 - 90 °F), start the engine and set the heater-A/C mode control switch in any A/C position. If the compressor clutch fails to engage, use a DRB III scan tool and the proper Diagnostic Procedures to check the Powertrain Control Module (PCM) and its inputs and outputs. If the compressor clutch engages, the clutch should cycle on and off two to three times per minute. If the clutch fails to cycle at this rate in these ambient temperatures, replace the faulty electronic cycling clutch switch. NOTE: It the ambient temperature is above 32 °C (90 °F) the compressor clutch may stay engaged and not cycle due to the high heat load. This condition is normal. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Electronic Cycling Clutch Switch Replacement Low Pressure Sensor / Switch: Service and Repair Electronic Cycling Clutch Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Electronic Cycling Clutch Switch Remove/Install 2. Unplug the wire harness connector from the electronic cycling clutch switch near the expansion valve. 3. Remove and discard the fastener that secures the electronic cycling clutch switch to the outboard side of the expansion valve. 4. Pull the electronic cycling clutch switch away from the side of the expansion valve far enough for the thermistor probe capillary tube to clear the well in the expansion valve. The washer bottle may have to be removed. NOTE: The capillary tube well in the expansion valve is tilled with a special thermally-conductive grease. This grease should be removed from the old parts and reused on the new parts whenever the electronic cycling clutch switch or the expansion valve are replaced. INSTALLATION 1. Insert the thermistor probe capillary tube of the electronic cycling clutch switch into the well on the outboard side of the expansion valve. 2. Install the electronic cycling clutch switch to the expansion valve and secure it with a new fastener. 3. Plug the wire harness connector into the electronic cycling clutch switch. 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Electronic Cycling Clutch Switch Replacement > Page 431 Low Pressure Sensor / Switch: Service and Repair Low Pressure Cut-Out Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Low Pressure Cut-Off Switch Remove/Install 2. Unplug the wire harness connector from the low pressure cut-off switch on the suction line jumper near the expansion valve. 3. Unscrew the low pressure cut-off switch from the fitting on the suction line jumper. 4. Remove the O-ring seal from the suction line jumper fitting and discard. INSTALLATION 1. Lubricate a new O-ring seal with clean refrigerant oil and install it on the suction line jumper 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 low pressure cut-off switch on the suction line jumper fitting. The switch should be hand-tightened onto the fitting. 3. Plug the wire harness connector into the low pressure cut-off switch. 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams Multi-Function Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 440 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 441 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 442 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 443 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 444 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 445 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 446 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 447 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 448 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 449 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 450 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 451 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 452 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 453 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 454 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 455 Door Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 456 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 457 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 458 Compass/Mini-Trip Computer Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 459 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 460 Door Switch: Description and Operation SYSTEM DESCRIPTION The driver door ajar switch is integral to the driver side front door latch. The switch closes a path to ground for the Central Timer Module (CTM) when the driver door is opened, and opens the ground path when the driver door is closed. The driver door ajar switch cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 461 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Rotate the headlamp switch knob counterclockwise to ensure that the dome lamps are not switched off. Open the driver door and note whether the interior lamps light. They should light. If OK, see Key-In Ignition Switch and/or Headlamp Switch in the Diagnosis and Testing. If not OK, go to Step 2. 2. Disconnect and isolate the battery negative cable. Unplug the driver door latch wire harness connector. Check for continuity between the ground circuit cavity in the body half of the driver door latch wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the circuit to ground as required. 3. Check for continuity between the driver door ajar switch ground circuit terminal and the driver door ajar switch sense circuit terminal of the driver door latch wire harness connector. There should be continuity with the driver door open, and no continuity with the driver door closed. If OK, go to Step 4. If not OK, replace the faulty latch. 4. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the procedures. Unplug the 14-way CTM wire harness connector. Check for continuity between the driver door ajar switch sense circuit cavity of the 14-way CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5 If not OK, repair the short circuit as required. 5. Check for continuity between the driver door ajar switch sense circuit cavities of the 14-way CTM wire harness connector and the driver door latch wire harness connector. There should be continuity. If OK, see Key-In Ignition Switch and/or Headlamp Switch in the Diagnosis and Testing. If not OK, repair the open circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Component Locations Fuel Gauge Sender: Component Locations 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Component Locations > Page 466 Fuel Fill/Vent Tube Assembly, Rollover Valve, Fuel Pump Module, Fuel Tank, Fuel Filter/Fuel Pressure Regulator Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 467 Fuel Pump Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 468 Fuel Gauge Sender: Description and Operation Fuel Pump Module/Fuel Tank (Top View) Fuel Pump Module Components (Typical Pump Module Shown) FUEL PUMP MODULE The fuel pump module on all models/all engines is installed in the top of the fuel tank. The fuel pump module contains the following components. A combination fuel filter/fuel pressure regulator Electric fuel pump - Fuel pump reservoir - A separate in-tank fuel filter (at bottom of module) - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection at filter/regulator - A metal lock-ring to retain pump module to fuel tank - A gasket between tank flange and module The fuel gauge sending unit (fuel level sensor), and pick-up filter (at bottom of module) may be serviced separately. If the electrical fuel pump requires service, the entire fuel pump module must be replaced. The fuel filter/fuel pressure regulator may be serviced separately. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. FUEL GAUGE SENDING UNIT 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). The resistor track is used to send electrical signals to the Powertrain Control Module (PCM) for fuel gauge operation and for OBDII emission requirements. For fuel gauge operation: As fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge to read full. As fuel level decreases, the float and arm move down. This increases the sending unit resistance causing the fuel gauge to read empty. After this fuel level signal is sent to the PCM, the PCM will transmit the data across the CCD bus circuits to the instrument panel. Here it is translated into the appropriate fuel gauge level reading. For OBD II emission monitor requirements: A voltage signal is sent from the resistor track on the sending unit to the PCM to indicate fuel level. The purpose of this feature is to prevent the OBDII system from recording/setting false misfire and fuel system monitor 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 469 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 470 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 ohms. With float in down position, resistance should be 220 ohms ± 6 ohms. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Gauge Sending Unit Replacement Fuel Gauge Sender: Service and Repair Fuel Gauge Sending Unit Replacement 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. REMOVAL 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/installation. 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. Fuel Gauge Sending Unit Lock Tab/Tracks 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 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. Refer to Fuel Pump Module Removal/Installation. 6. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Gauge Sending Unit Replacement > Page 473 Fuel Gauge Sender: Service and Repair Fuel Pump Module Replacement REMOVAL WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING FUEL PUMP MODULE, FUEL SYSTEM PRESSURE MUST BE RELEASED. The fuel pump module is located in top of fuel tank. 1. Drain fuel tank and remove tank. Refer to Fuel Tank Removal/lnstallation. 2. Thoroughly wash and clean area around pump module to prevent contaminants from entering tank. Fuel Pump Module And Locking 3. Part of Fuel Tank Removal Procedure: Disconnect EVAP line at pump module; disconnect wiring harness connector at pump module; disconnect fuel line from fuel filter fitting. 4. Rotate fuel filter until its fitting is pointed towards center of pump module. 5. A metal lockring is used to secure fuel pump module to fuel tank. Six metal fingers are molded into the plastic fuel tank. The fingers are used to retain lockring to fuel tank. A rubber gasket is used as a seal between module and fuel tank. 6. Before removing lockring, apply a small amount of engine oil to 6 fingers where fingers meet lockring (to act as a lubricant). 7. Remove (rotate) lockring counterclockwise using a brass or bronze drift punch and a hammer. This must be done while slightly prying back on lock tab. 8. Remove lockring and pump module from fuel tank. INSTALLATION CAUTION: Whenever fuel pump module is serviced, the module gasket must be replaced. 1. Using a new gasket, position fuel pump module into opening in fuel tank. Be sure rubber gasket remains in place. Rotate pump module assembly until module is positioned as shown in. This step must be followed to prevent float/float rod from contacting sides of fuel tank. 2. Before installing lockring, apply a small amount of engine oil to 6 fingers where fingers meet lockring (to act as a lubricant). 3. Position lockring over top of fuel pump module. Tighten finger tight. 4. Install (rotate) lockring clockwise using a brass or bronze drift punch and a hammer. Continue rotating lockring until 6 fingers drop into 6 finger locks and lock tab falls into lockring notch. 5. Install fuel tank. Refer to Fuel Tank Installation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key-In Ignition Switch <--> [Key Reminder Switch] > Component Information > Description and Operation Key-In Ignition Switch: Description and Operation The key-in ignition switch is integral to the ignition switch, which is mounted on the right side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition lock cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition lock cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key-In Ignition Switch <--> [Key Reminder Switch] > Component Information > Description and Operation > Page 477 Key-In Ignition Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. Remove the steering column shrouds. Unplug the key-in ignition switch wire harness connector from the ignition switch. 2. Check for continuity between the key-in ignition switch sense and ground terminals of the key-in ignition switch. There should be continuity with the key in the ignition lock cylinder, and no continuity with the key removed from the ignition lock cylinder. If OK, go to Step 3. If not OK, replace the faulty ignition switch assembly. 3. Open the driver door. Check for continuity between the ground circuit cavity of the key-in ignition 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 the driver door ajar switch as required. 4. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the procedures. Unplug the 14-way CTM wire harness connector. Close the driver door. Check for continuity between the key-in ignition switch sense circuit cavity of the CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the short circuit as required. 5. Check for continuity between the key-in ignition switch sense circuit cavities of the key-in ignition switch wire harness connector and the 14-way CTM wire harness connector. There should be continuity. If OK, test the CTM as described. If not OK, repair the open circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Transmission Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Lighting - Stop Lamp Switch Service Revisions Brake Light Switch: Technical Service Bulletins Lighting - Stop Lamp Switch Service Revisions NUMBER: 26-05-99A GROUP: Miscellaneous DATE: May, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1999 Durango Service Manual - Publication Number 81-370-9116 DESCRIPTION OF CHANGES Revisions to the Stop Lamp Switch Service Procedures Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Lighting - Stop Lamp Switch Service Revisions > Page 486 5-2 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Lighting - Stop Lamp Switch Service Revisions > Page 487 5-12 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 488 Brake Lamp Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 489 Brake Lamp Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > With Antilock Brakes Brake Light Switch: Description and Operation With Antilock Brakes The primary function of the switch is to turn on the stop 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. When the brake light switch is activated, the Powertrain Control Module (PCM) receives an input indicating that the brakes are being applied. After receiving this input, the PCM maintains idle speed to a scheduled rpm through control of the Idle Air Control (IAC) motor. The brake switch input is also used to disable vent and vacuum solenoid output signals to the speed control servo. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > With Antilock Brakes > Page 492 Brake Light Switch: Description and Operation With Standard Brakes The content of this article reflects the changes called out by TSB 26-05-99. The stop lamp switch is mounted on a bracket on 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 493 Brake Light Switch: Testing and Inspection The stop lamp switch has a 12 volt feed circuit from the fuse block. Verify fuse is OK, then check the feed from the fuse block to the switch. If the switch has 12 volts depress the brake pedal and check for voltage to the stop lamp circuit. If no voltage is present the switch must be replaced. If the switch does not have 12 volts from the fuse block check for continuity between the fuse block the switch and repair as necessary. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 494 Brake Light Switch: Service and Repair The content of this article reflects the changes called out by TSB 26-05-99. REMOVAL Stop Lamp Switch & Bracket 1. Disconnect switch harness. 2. Press and hold brake pedal in applied position. 3. Rotate switch counterclockwise about 30° 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. Install switch. Align tab on 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 499 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 500 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 501 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 502 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 503 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 504 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 505 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 506 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 507 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 508 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 509 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 510 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 511 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 512 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 513 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 514 Door Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 515 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 516 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 517 Compass/Mini-Trip Computer Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 518 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 519 Door Switch: Description and Operation SYSTEM DESCRIPTION The driver door ajar switch is integral to the driver side front door latch. The switch closes a path to ground for the Central Timer Module (CTM) when the driver door is opened, and opens the ground path when the driver door is closed. The driver door ajar switch cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 520 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Rotate the headlamp switch knob counterclockwise to ensure that the dome lamps are not switched off. Open the driver door and note whether the interior lamps light. They should light. If OK, see Key-In Ignition Switch and/or Headlamp Switch in the Diagnosis and Testing. If not OK, go to Step 2. 2. Disconnect and isolate the battery negative cable. Unplug the driver door latch wire harness connector. Check for continuity between the ground circuit cavity in the body half of the driver door latch wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the circuit to ground as required. 3. Check for continuity between the driver door ajar switch ground circuit terminal and the driver door ajar switch sense circuit terminal of the driver door latch wire harness connector. There should be continuity with the driver door open, and no continuity with the driver door closed. If OK, go to Step 4. If not OK, replace the faulty latch. 4. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the procedures. Unplug the 14-way CTM wire harness connector. Check for continuity between the driver door ajar switch sense circuit cavity of the 14-way CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5 If not OK, repair the short circuit as required. 5. Check for continuity between the driver door ajar switch sense circuit cavities of the 14-way CTM wire harness connector and the driver door latch wire harness connector. There should be continuity. If OK, see Key-In Ignition Switch and/or Headlamp Switch in the Diagnosis and Testing. If not OK, repair the open circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Locations Glove Box Lamp And Switch Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Locations > Page 524 Glove Box Lamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Locations > Page 525 Glove Box Lamp Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. REMOVAL 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications Hazard Warning Switch: Specifications Tighten the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle to 2 Nm (17 in. lbs.). Tighten the two screws that secure the multi-function switch to the steering column to 2 Nm (17 in. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 529 Multi-Function Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 530 Hazard Warning Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 531 Hazard Warning Switch: Description and Operation DESCRIPTION Multi-Function Switch The turn signal and hazard warning switches are integral to the multi-function switch unit, which is secured to the left side of the steering column. The only visible parts of the multi-function switch are the control stalk that extends from the left side of the steering column, and the hazard warning switch push button that protrudes from the top of the steering column. The multi-function switch control stalk has both nomenclature and international control symbols on it, which identify its many functions. The hazard warning switch push button is identified with a double triangle, which is the international control symbol for hazard warning. The remainder of the multi-function switch is concealed beneath the steering column shrouds. The multi-function switch also contains circuitry for the following functions: Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information addresses only the multi-function switch turn signal and hazard warning functions. However, the turn signal and hazard warning switches cannot be repaired. If these switches or any other circuit or component of the multi-function switch unit is faulty or damaged, the entire multifunction switch unit must be replaced. OPERATION The hazard warning switch is controlled by the hazard warning switch push button. Push the switch button in to unlatch the switch and activate the hazard warning system, and push in on the button again to latch the switch and turn the system off. When the hazard waring 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 532 Hazard Warning Switch: Testing and Inspection The turn signal switch and the hazard warning switch are integral to the multi-function switch. Refer to Turn Signal and Hazard Warning Systems in the Diagnosis and Testing before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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 instrument panel wire harness connector from the multi-function switch connector receptacle. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the connector receptacle terminals as shown in the Multi-Function Switch Continuity chart. 3. If the turn signal switch or hazard warning switch fails any of the continuity checks, replace the faulty multi-function switch assembly as required. If the switch circuits are OK, repair the lighting circuits as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 533 Hazard Warning Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt lever from the left side of the steering column. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud from the steering column. Multifunction Switch 5. Move the upper fixed column shroud far enough to access the back of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof Torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the multi-function switch away from the steering column far enough to access and remove the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. 8. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. 9. Remove the multi-function switch from the steering column. INSTALLATION 1. Position the multi-function switch onto the steering column. 2. Reconnect the instrument panel wire harness connector to the multi-function switch connector receptacle. 3. Install and tighten the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. Tighten the screw to 2 Nm (17 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 534 4. Install and tighten the two screws that secure the multi-function switch to the steering column. Tighten the screws to 2 Nm (17 in. lbs.) 5. Install the lower fixed column shroud onto the steering column. 6. Install both the upper and lower shrouds onto the steering column. 7. If the vehicle is so equipped, install the tilt lever onto the left side of the steering column. 8. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications Headlamp Switch: Specifications Headlamp Switch to Instrument Panel Screws (3) 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications > Page 538 Headlamp Switch: Locations Headlamp Switch Remove/Install The headlamp switch is located in the instrument panel, outboard of the steering column. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications > Page 539 Multi-Function Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications > Page 540 Headlamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications > Page 541 Headlamp Switch: Description and Operation SYSTEM DESCRIPTION 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). The headlamp switch cannot be repaired and, if faulty or damaged, it must be replaced. Refer to Headlamp Switch/Service and Repair of Instrument Panel Systems for the service procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications > Page 542 Headlamp Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. Remove the headlamp switch from the instrument panel. Refer to Headlamp Switch/Service and Repair of Instrument Panel Systems for the procedures. Unplug the headlamp switch wire harness connectors. Check for continuity between the driver door ajar switch sense circuit cavity of the headlamp switch wire harness connector and a good ground. There should be continuity with the driver door open, and no continuity with the driver door closed. If OK, go to Step 2. If not OK, repair the circuit to the driver door ajar switch as required. 2. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the procedures. Unplug the 14-way CTM wire harness connector. Remove the key from the ignition lock cylinder. Check for continuity between the key-in ignition switch sense circuit cavity of the 14-way CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 3. If not OK, repair the short circuit as required. 3. Check for continuity between the key-in ignition switch sense circuit cavities of the 14-way CTM wire harness connector and the headlamp switch wire harness connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open circuit as required. 4. Check for continuity between the driver door ajar switch sense circuit terminal and the key-in ignition switch sense circuit terminal of the headlamp switch. There should be no continuity with the switch in the Off position, and continuity with the switch in the park or head lamps On position. If OK, see Central Timer Module in the Diagnosis and Testing. If not OK, replace the faulty headlamp switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications > Page 543 Headlamp Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. Refer to Cluster Bezel Replacement for the procedures. Headlamp Switch Remove/Install 3. Remove the three screws that secure the headlamp switch to the instrument panel. 4. Pull the headlamp switch away from the instrument panel far enough to access the instrument panel wire harness connectors. 5. Disconnect the two instrument panel wire harness connectors from the headlamp switch connector receptacles. 6. Remove the headlamp switch from the instrument panel. INSTALLATION 1. Position the headlamp switch to the instrument panel. 2. Reconnect the two instrument panel wire harness connectors to the headlamp switch connector receptacles. 3. Install the headlamp switch into the instrument panel. 4. Install and tighten the three screws that secure the headlamp switch to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 5. Install the cluster bezel onto the instrument panel. Refer to Cluster Bezel Replacement for the procedures. 6. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Driver Side Airbag Module Trim Cover And Horn Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 547 Horn Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 548 Horn Switch: Description and Operation DESCRIPTION Airbag Trim Cover Remove/Install 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. OPERATION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 549 Horn Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. 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. If not OK, refer to Steering Column/Service and Repair of Steering for proper installation of the steering column. 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 Power Distribution Center (PDC). 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 PDC 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 PDC. 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 PDC 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications Turn Signal Switch: Specifications Instrument Panel Wiring Harness Connector to Multi-Function Switch Connector Receptacle Screw 17 in.lb Multi-Function Switch to Steering Column Screws (2) 17 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 553 Multifunction Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 554 Multi-Function Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 555 Turn Signal Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 556 Turn Signal Switch: Description and Operation DESCRIPTION Multi-Function Switch The turn signal and hazard warning switches are integral to the multi-function switch unit, which is secured to the left side of the steering column. The only visible parts of the multi-function switch are the control stalk that extends from the left side of the steering column, and the hazard warning switch push button that protrudes from the top of the steering column. The multi-function switch control stalk has both nomenclature and international control symbols on it, which identify its many functions. The hazard warning switch push button is identified with a double triangle, which is the international control symbol for hazard warning. The remainder of the multi-function switch is concealed beneath the steering column shrouds. The multi-function switch also contains circuitry for the following functions: Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained in this addresses only the multi-function switch turn signal and hazard warning functions. However, the turn signal and hazard warning switches cannot be repaired. If these switches or any other circuit or component of the multi-function switch unit is faulty or damaged, the entire multifunction switch unit must be replaced. OPERATION The multi-function switch control stalk that extends from the left side of the steering column just below the steering wheel is moved up or down to activate the turn signal switch. When the control stalk is moved in the upward direction, the right turn signal switch circuitry is activated; and, when the control stalk is moved in the downward direction, the left turn signal switch circuitry is activated. 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 turn signal switch is in a detent position, it is turned off by one of two turn signal cancelling cam lobes that are integral to the rotor of the clockspring mechanism. Turning the steering wheel causes the turn signal cancelling cam lobes to contact a cancel actuator in the multi-function switch, and the turn signal switch automatically returns to the off position. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 557 Turn Signal Switch: Testing and Inspection The turn signal switch and the hazard warning switch are integral to the multi-function switch. Refer to Turn Signal and Hazard Warning Systems in the Diagnosis and Testing before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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 instrument panel wire harness connector from the multi-function switch connector receptacle. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the connector receptacle terminals as shown in the Multi-Function Switch Continuity chart. 3. If the turn signal switch or hazard warning switch fails any of the continuity checks, replace the faulty multi-function switch assembly as required. If the switch circuits are OK, repair the lighting circuits as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 558 Turn Signal Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt lever from the left side of the steering column. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud from the steering column. Multifunction Switch 5. Move the upper fixed column shroud far enough to access the back of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof Torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the multi-function switch away from the steering column far enough to access and remove the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. 8. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. 9. Remove the multi-function switch from the steering column. INSTALLATION 1. Position the multi-function switch onto the steering column. 2. Reconnect the instrument panel wire harness connector to the multi-function switch connector receptacle. 3. Install and tighten the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. Tighten the screw to 2 Nm (17 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 559 4. Install and tighten the two screws that secure the multi-function switch to the steering column. Tighten the screws to 2 Nm (17 in. lbs.) 5. Install the lower fixed column shroud onto the steering column. 6. Install both the upper and lower shrouds onto the steering column. 7. If the vehicle is so equipped, install the tilt lever onto the left side of the steering column. 8. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Battery Temperature Sensor The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 565 Battery Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 566 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 567 Battery Temperature Sensor: Description and Operation DESCRIPTION The battery temperature sensor is attached to the battery tray located under the battery. OPERATION The battery temperature sensor 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. BATTERY TEMPERATURE SENSOR-PCM INPUT Provides a signal to the PCM corresponding to the battery temperature. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor 1. The sensor is located on the front of the battery tray. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25° C (75-80° F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 570 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. REMOVAL 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor Oil Pressure Sending Unit/Switch, Camshaft Position Sensor Connector The camshaft position sensor is located in the distributor on all engines. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 574 Camshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 575 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor CAMSHAFT POSITION SENSOR - PCM INPUT A sync signal is provide by the camshaft position sensor located in the distributor. The sync signal from this sensor works in conjunction with the crankshaft position sensor to provide the Powertrain Control Module (PCM) with inputs. This is done to establish and maintain correct injector firing order. CAMSHAFT POSITION SENSOR The camshaft position sensor is located in the distributor on all engines. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 576 Camshaft Position Sensor: Testing and Inspection Camshaft Position Sensor The camshaft position sensor is located in the distributor on all engines. To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: For this test, an analog (non-digital) voltmeter is needed. Do not remove the distributor connector from the distributor. Using small paper clips, insert them into the backside of the distributor wire harness connector to make contact with the terminals. Be sure that the connector is not damaged when inserting the paper clips. Attach voltmeter leads to these paper clips. 1. Connect the positive (+) voltmeter lead into the sensor output wire. This is at done the distributor wire harness connector. 2. Connect the negative (-) voltmeter lead into the ground wire. 3. Set the voltmeter to the 15 Volt DC scale. 4. Remove distributor cap from distributor (two screws). Rotate (crank) the engine until the distributor rotor is pointed towards the rear of vehicle. The movable pulse ring should now be within the sensor pickup. 5. Turn ignition key to ON position. Voltmeter should read approximately 5.0 volts. 6. If voltage is not present, check the voltmeter leads for a good connection. 7. If voltage is still not present, check for voltage at the supply wire. For wire identification, refer to Wiring Diagrams. 8. If 5 volts is not present at supply wire, check for voltage at PCM 32-way connector (cavity A-17). Leave the PCM connector connected for this test. 9. If voltage is still not present, perform vehicle test using the DRB scan tool. 10. If voltage is present at cavity A-17, but not at the supply wire: a. Check continuity between the supply wire. This is checked between the distributor connector and cavity A-17 at the PCM. If continuity is not present, repair the harness as necessary. b. Check for continuity between the camshaft position sensor output wire and cavity A-18 at the PCM, If continuity is not present, repair the harness as necessary. c. Check for continuity between the ground circuit wire at the distributor connector and ground. If continuity is not present, repair the harness as necessary. 11. While observing the voltmeter, crank the engine with ignition switch. The voltmeter needle should fluctuate between 0 and 5 volts while the engine is cranking. This verifies that the camshaft position sensor in the distributor is operating properly and a sync pulse signal is being generated. If sync pulse signal is not present, replacement of the camshaft position sensor is necessary Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 577 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor The camshaft position sensor is located in the distributor on all engines. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove air cleaner assembly. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. tighten mounting screws. 5. Install air cleaner assembly. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 11 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 581 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor-Typical Intake Air Temperature Sensor, Engine Coolant Temperature Sensor Connector, Ignition Coil The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 582 Engine Coolant Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 583 Coolant Temperature Sensor/Switch (For Computer): Service Precautions WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 584 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT The engine coolant temperature sensor is installed into a water jacket at the front of the intake manifold located near the rear of the generator. The sensor provides an input voltage to the Powertrain Control Module (PCM) relating coolant temperature. The PCM uses this input along with inputs from other sensors to determine injector pulse width and ignition timing. As coolant temperature varies, the coolant temperature sensor resistance will change. This change in resistance results in a different input voltage to the PCM. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 585 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: Engine Coolant Temperature Sensor-Typical 1. Disconnect wire harness connector from coolant temperature sensor. 2. Engines with air conditioning: When removing the connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place the hook part of tool under the connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. Sensor Resistance(Ohms)-Coolant Temperature Sensor/Intake Air Temperature Sensor 3. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. The resistance (as measured across the sensor terminals) should be as shown in the SENSOR RESISTANCE (OHMS)-COOLANT TEMPERATURE SENSOR/INTAKE AIR TEMPERATURE SENSOR resistance chart. Replace the sensor if it is not within the range of resistance specified in the chart. 4. Test continuity of the wire harness between the PCM wire harness connector and the coolant sensor connector terminals. Refer to Wiring for terminal/cavity locations. Repair the wire harness if an open circuit is indicated. 5. After tests are completed, connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 586 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor-Typical The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain cooling system. 2. Disconnect electrical connector from sensor. 3. Engines with air conditioning: When removing the connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place the hook part of tool under the connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Use long needle nose pliers to connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. 4. Replace any lost engine coolant. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor 8 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 590 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The sensor is bolted to the cylinder block near the rear of the right cylinder head. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 591 Crankshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 592 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR 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. Sensor Operation The flywheel/drive plate has 8 single notches, spaced every 45 degrees, 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. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a crankshaft position sensor input. CRANKSHAFT POSITION SENSOR-PCM INPUT This sensor is a hall effect device that detects notches in the flywheel (manual transmission) or flexplate (automatic transmission). This sensor is used to indicate to the Powertrain Control Module (PCM) that a spark and or fuel injection event is to be required. The output from this sensor, in conjunction with the camshaft position sensor signal, is used to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 593 Crankshaft Position Sensor The sensor is bolted to the cylinder block near the rear of the right cylinder head. Refer to Ignition System for more crankshaft position sensor information. The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 594 Crankshaft Position Sensor: Testing and Inspection To perform a complete test of this sensor and its circuitry, refer to the DRB scan tool. Also refer to the appropriate Powertrain Diagnostics Procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 595 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. 1. Remove right front tire and right front wheelhouse liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheelhouse liner. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR-PCM INPUT The Powertrain Control Module (PCM) supplies power to the fuel level sensor (fuel gauge sending unit). The fuel level sensor will then return a signal to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes. This is if the fuel level is less than approximately 15 percent, or, if equipped with a Leak Detection Pump (LDP), more than approximately 85 percent of its rated capacity. This input is also used to send a signal to the PCM for fuel gauge operation via the CCD bus circuits. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Intake Manifold Air Temperature Sensor 28 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 602 Intake Air Temperature Sensor: Locations Intake Manifold Air Temperature Sensor-Typical Intake Air Temperature Sensor, Engine Coolant Temperature Sensor Connector, Ignition Coil The intake manifold air temperature sensor is located in the front/side of the intake manifold. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 603 Intake Air Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 604 Intake Air Temperature Sensor: Description and Operation Intake Manifold Air Temperature Sensor INTAKE MANIFOLD AIR TEMPERATURE SENSOR-PCM INPUT The intake manifold air temperature sensor is installed in the intake manifold with the sensor element extending into the air stream. The sensor provides an input voltage to the Powertrain Control Module (PCM) indicating intake manifold air temperature. The input is used along with inputs from other sensors to determine injector pulse width. As the temperature of the air-fuel stream in the manifold varies, the sensor resistance changes. This results in a different input voltage to the PCM. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 605 Intake Air Temperature Sensor: Testing and Inspection To perform a complete test of the intake manifold air temperature sensor and its circuitry, refer to DRB tester and appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: Intake Manifold Air Temperature Sensor 1. Disconnect the wire harness connector from the intake manifold air temperature sensor. Sensor Resistance(Ohms)-Coolant Temperature Sensor/Intake Air Temperature Sensor 2. Test the resistance of the sensor with an input impedance (digital) volt-ohmmeter. The resistance (as measured across the sensor terminals) should be as shown in the previous SENSOR RESISTANCE (OHMS-COOLANT TEMPERATURE SENSOR/INTAKE AIR TEMPERATURE SENSOR chart. Replace the sensor if it is not within the range of resistance specified in the chart. 3. Test the resistance of the wire harness. Do this between the PCM wire harness connector A-15 and the sensor connector terminal. Also check between PCM connector A-4 to the sensor connector terminal. Repair the wire harness as necessary if the resistance is greater than 1 ohm. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 606 Intake Air Temperature Sensor: Service and Repair Intake Manifold Air Temperature Sensor-Typical The intake manifold air temperature sensor is located in the front/side of the intake manifold. REMOVAL 1. Remove air duct at throttle body. 2. Disconnect electrical connector at sensor 3. Remove sensor from intake manifold. INSTALLATION 1. Install sensor to intake manifold. Tighten to 28 Nm (20 ft. lbs.) torque. 2. Install electrical connector. 3. Install air duct at throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications MAP Sensor Mounting Screws 3 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 610 Manifold Pressure/Vacuum Sensor: Locations MAP And Throttle Position Sensor Location The MAP sensor is mounted on the side of the engine throttle body. The sensor is connected to the throttle body with a rubber L-shaped fitting. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 611 Manifold Absolute Pressure Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 612 Manifold Pressure/Vacuum Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR-PCM INPUT The MAP sensor reacts to absolute pressure in the intake manifold. It provides an input voltage to the Powertrain Control Module (PCM). As engine load changes, manifold pressure varies. The change in manifold pressure causes MAP sensor voltage to change. The change in MAP sensor voltage results in a different input voltage to the PCM. The input voltage level supplies the PCM with information about ambient barometric pressure during engine start-up (cranking) and engine load while the engine is running. The PCM uses this input along with inputs from other sensors to adjust air-fuel mixture. MAP And Throttle Position Sensor Location The MAP sensor is mounted on the side of the engine throttle body. The sensor is connected to the throttle body with a rubber L-shaped fitting. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 613 Manifold Pressure/Vacuum Sensor: Testing and Inspection MAP Sensor-Typical To perform a complete test of MAP sensor and its circuitry, refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the MAP sensor only, refer to the following: Rubber L-shaped Fitting-MAP Sensor-to-Throttle Body 1. Inspect the rubber L-shaped fitting from the MAP sensor to the throttle body. Repair as necessary. CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 614 MAP Sensor Connector Terminals-Typical 2. Test the MAP sensor output voltage at the MAP sensor connector between terminals A and B. With the ignition switch ON and the engine OFF, output voltage should be 4-to-5 volts. The voltage should drop to 1.5-to-2.1 volts with a hot, neutral idle speed condition. 3. Test Powertrain Control Module (PCM) cavity A-27 for the same voltage described above to verify the wire harness condition. Repair as necessary. 4. Test MAP sensor supply voltage at sensor connector between terminals A and C with the ignition ON. The voltage should be approximately 5 volts (± 0.5V). Five volts (± 0.5V) should also be at cavity A-17 of the PCM wire harness connector. Repair or replace the wire harness as necessary. 5. Test the MAP sensor ground circuit at sensor connector terminal-A and PCM connector A-4. Repair the wire harness if necessary Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 615 Manifold Pressure/Vacuum Sensor: Service and Repair MAP Sensor Location MAP Sensor L-Shaped Rubber Fitting The MAP sensor is located on the front of the throttle body. An L-shaped rubber fitting is used to connect the MAP sensor to throttle body. REMOVAL 1. Remove air duct at throttle body. 2. Remove two MAP sensor mounting bolts (screws). 3. While removing MAP sensor, slide the vacuum rubber L-shaped fitting from the throttle body. 4. Remove rubber L-shaped fitting from MAP sensor. INSTALLATION 1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple. 3. Install MAP sensor mounting bolts (screws). Tighten screws to 3 Nm (25 in. lbs.) torque. 4. Install air duct at throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 619 Oil Pressure Sensor: Description and Operation OIL PRESSURE SENSOR-PCM INPUT Sends a signal from the oil pressure sending unit to the Powertrain Control Module (PCM) relating to engine oil pressure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 625 Oxygen Sensor: Locations Oxygen Sensor(s) Upstream Oxygen Sensor Locations Oxygen Sensor The upstream O2S sensor is located on exhaust downpipe. Downstream Oxygen Sensor Location Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 626 Downstream Oxygen Sensor The downstream O2S sensor is located on the outlet end of the catalytic converter. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 627 Oxygen Sensor: Diagrams Oxygen Sensor (Sensor Side) Oxygen Sensor 1/1 Upstream Oxygen Sensor 1/2 Downstream Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 628 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 629 Oxygen Sensor: Application and ID Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 630 Oxygen Sensor: Description and Operation OXYGEN SENSOR-PCM INPUT Two heated O2S sensors are used. The sensors produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel mixture), the sensors produces a low voltage. When there is a lesser amount present (rich air/fuel mixture) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. In Closed Loop operation, the PCM monitors the 02S sensor input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the 02 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. 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. The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. UPSTREAM HEATED OXYGEN SENSOR The upstream O2S sensor is located near the inlet end of the catalytic converter. It 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 the air/fuel ratio by adjusting injector pulse width. DOWNSTREAM HEATED OXYGEN SENSOR The downstream heated oxygen sensor is located near the outlet end of the catalytic converter. The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the Malfunction Indicator Lamp (MIL). For more information, refer to Emission Control Systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 631 Oxygen Sensor: Testing and Inspection To perform a complete test of the 02S sensors and their circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the O2S sensors only, refer to the following: Upstream Oxygen Sensor Location The upstream O2S sensor is located on the exhaust pipe. Downstream Oxygen Sensor Location The downstream O2S sensor is located on the outlet end of the catalytic converter. Each O2S heating element can be tested with an ohmmeter as follows: Disconnect the O2S sensor connector. Connect the ohmmeter test leads across the white wire terminals of the sensor connector. Resistance should be between 4.5 ± 0.5 ohms and 7 ohms. Replace the sensor if the ohmmeter displays an infinity (open) reading. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 632 Oxygen Sensor: Service and Repair Upstream Oxygen Sensor Locations Downstream Oxygen Sensor Locations The upstream O2S sensor is located on exhaust downpipe. The downstream sensor is located near outlet end of catalytic converter. REMOVAL WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support the vehicle. 2. Disconnect the wire connector from the O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install the O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 636 Throttle Position Sensor: Locations MAP And Throttle Position Sensor Location The throttle position sensor (TPS) is mounted on the throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 637 Throttle Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 638 Throttle Position Sensor: Description and Operation MAP And Throttle Position Sensor Location THROTTLE POSITION SENSOR (TPS)-PCM INPUT The throttle position sensor (TPS) is mounted on the throttle body. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents throttle blade position. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 639 Throttle Position Sensor: Testing and Inspection To perform a complete test of the TPS and its circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the TPS only, refer to the following: Throttle Position Sensor The TPS can be tested with a digital voltmeter. The center electrical terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). At idle, TPS output voltage should be greater than 0.26 volts but less than 0.95 volts. At wide open throttle, TPS output voltage must be less than 4.49 volts. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 640 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on side of throttle body. 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body. INSTALLATION Installation-Typical The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 644 Transmission Position Switch/Sensor: Description and Operation TRANSMISSION PARK/NEUTRAL SWITCH-PCM INPUT The park/neutral switch is located on the transmission housing and provides an input to the Powertrain Control Module (PCM), This will indicate that the automatic transmission is in Park, Neutral or a drive gear selection. This input is used to determine idle speed (varying with gear selection), fuel injector pulse width, ignition timing advance and vehicle speed control operation. The center terminal of the park/neutral position switch is the starter-circuit terminal. It provides the ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. The outer terminals on the switch are for the backup lamp circuit. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 645 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for speed control system operation. For the location of the transmission output shaft sensor, please refer to Transmission Speed Sensor/Locations. See: Sensors and Switches - Transmission and Drivetrain/Sensors and Switches - A/T/Transmission Speed Sensor For the location of the rear wheel speed sensor, please refer to Brakes and Traction Control/Brakes/Antilock Brake System/Wheel Speed Sensor/Locations. See: Sensors and Switches - Brakes and Traction Control/Wheel Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 651 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 652 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 653 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 654 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 655 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 656 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 657 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 658 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 659 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 660 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 661 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 662 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 663 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 664 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 665 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 666 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 667 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 668 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 669 Vehicle Speed Sensor: Description and Operation VEHICLE SPEED AND DISTANCE-PCM INPUT Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for fuel system and speed control system operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 674 Throttle Position Sensor: Locations MAP And Throttle Position Sensor Location The throttle position sensor (TPS) is mounted on the throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 675 Throttle Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 676 Throttle Position Sensor: Description and Operation MAP And Throttle Position Sensor Location THROTTLE POSITION SENSOR (TPS)-PCM INPUT The throttle position sensor (TPS) is mounted on the throttle body. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents throttle blade position. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 677 Throttle Position Sensor: Testing and Inspection To perform a complete test of the TPS and its circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the TPS only, refer to the following: Throttle Position Sensor The TPS can be tested with a digital voltmeter. The center electrical terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). At idle, TPS output voltage should be greater than 0.26 volts but less than 0.95 volts. At wide open throttle, TPS output voltage must be less than 4.49 volts. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 678 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on side of throttle body. 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body. INSTALLATION Installation-Typical The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor Oil Pressure Sending Unit/Switch, Camshaft Position Sensor Connector The camshaft position sensor is located in the distributor on all engines. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 683 Camshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 684 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor CAMSHAFT POSITION SENSOR - PCM INPUT A sync signal is provide by the camshaft position sensor located in the distributor. The sync signal from this sensor works in conjunction with the crankshaft position sensor to provide the Powertrain Control Module (PCM) with inputs. This is done to establish and maintain correct injector firing order. CAMSHAFT POSITION SENSOR The camshaft position sensor is located in the distributor on all engines. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 685 Camshaft Position Sensor: Testing and Inspection Camshaft Position Sensor The camshaft position sensor is located in the distributor on all engines. To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: For this test, an analog (non-digital) voltmeter is needed. Do not remove the distributor connector from the distributor. Using small paper clips, insert them into the backside of the distributor wire harness connector to make contact with the terminals. Be sure that the connector is not damaged when inserting the paper clips. Attach voltmeter leads to these paper clips. 1. Connect the positive (+) voltmeter lead into the sensor output wire. This is at done the distributor wire harness connector. 2. Connect the negative (-) voltmeter lead into the ground wire. 3. Set the voltmeter to the 15 Volt DC scale. 4. Remove distributor cap from distributor (two screws). Rotate (crank) the engine until the distributor rotor is pointed towards the rear of vehicle. The movable pulse ring should now be within the sensor pickup. 5. Turn ignition key to ON position. Voltmeter should read approximately 5.0 volts. 6. If voltage is not present, check the voltmeter leads for a good connection. 7. If voltage is still not present, check for voltage at the supply wire. For wire identification, refer to Wiring Diagrams. 8. If 5 volts is not present at supply wire, check for voltage at PCM 32-way connector (cavity A-17). Leave the PCM connector connected for this test. 9. If voltage is still not present, perform vehicle test using the DRB scan tool. 10. If voltage is present at cavity A-17, but not at the supply wire: a. Check continuity between the supply wire. This is checked between the distributor connector and cavity A-17 at the PCM. If continuity is not present, repair the harness as necessary. b. Check for continuity between the camshaft position sensor output wire and cavity A-18 at the PCM, If continuity is not present, repair the harness as necessary. c. Check for continuity between the ground circuit wire at the distributor connector and ground. If continuity is not present, repair the harness as necessary. 11. While observing the voltmeter, crank the engine with ignition switch. The voltmeter needle should fluctuate between 0 and 5 volts while the engine is cranking. This verifies that the camshaft position sensor in the distributor is operating properly and a sync pulse signal is being generated. If sync pulse signal is not present, replacement of the camshaft position sensor is necessary Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 686 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor The camshaft position sensor is located in the distributor on all engines. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove air cleaner assembly. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. tighten mounting screws. 5. Install air cleaner assembly. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor 8 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 690 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The sensor is bolted to the cylinder block near the rear of the right cylinder head. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 691 Crankshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 692 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR 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. Sensor Operation The flywheel/drive plate has 8 single notches, spaced every 45 degrees, 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. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a crankshaft position sensor input. CRANKSHAFT POSITION SENSOR-PCM INPUT This sensor is a hall effect device that detects notches in the flywheel (manual transmission) or flexplate (automatic transmission). This sensor is used to indicate to the Powertrain Control Module (PCM) that a spark and or fuel injection event is to be required. The output from this sensor, in conjunction with the camshaft position sensor signal, is used to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 693 Crankshaft Position Sensor The sensor is bolted to the cylinder block near the rear of the right cylinder head. Refer to Ignition System for more crankshaft position sensor information. The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 694 Crankshaft Position Sensor: Testing and Inspection To perform a complete test of this sensor and its circuitry, refer to the DRB scan tool. Also refer to the appropriate Powertrain Diagnostics Procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 695 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. 1. Remove right front tire and right front wheelhouse liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheelhouse liner. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Removal/Installation. On vehicles equipped with an automatic transmission and a steering column mounted shifter an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced.. On vehicles equipped with an automatic transmission and a floor mounted shifter , a cable connects the interlock device within the steering column assembly, to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. The shifter interlock cable can be adjusted or replaced. SYSTEM DESCRIPTION The key-in ignition switch is integral to the ignition switch, which is mounted on the right side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition lock cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition lock cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 700 Ignition Switch Lock Cylinder: Service and Repair The ignition key must be in the key cylinder for cylinder removal. REMOVAL 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. Shroud Removal/Installation - Typical 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Retaining Pin 5. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 701 Flag In RUN Position Key Cylinder-Rear View Switch Mounting Screws 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 702 Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed. 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Ignition Switch View From Column Park Lock Linkage-Automatic Transmission-Typical Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 703 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkage before installing switch. Steering Wheel Lock Lever 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 3 Nm ± 0.5 Nm (26 in. lbs. ± 4 in. lbs.) torque. 11. Connect electrical connectors to ignition switch and halo lamp. Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). Tighten screws to 2 Nm (17 in. lbs.) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery. 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY; LOCK, OFF, ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify. Steering wheel should unlock when key is rotated to ON position. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 709 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 710 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 711 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 712 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 713 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 714 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 715 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 716 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 717 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 718 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 719 PARTS REQUIRED: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 720 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 721 POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Page 722 Passenger Airbag On/Off Switch C1 (Switch Side) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Service Precautions Seat Belt Buckle Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Service Precautions > Page 726 Seat Belt Buckle Switch: Description and Operation SYSTEM DESCRIPTION The driver seat belt switch is integral to the driver seat belt retractor assembly. The driver seat belt switch is normally closed, providing a ground signal to the instrument cluster when the ignition switch is in the On or Start positions. The seat belt switch monitors the amount of 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 opens the seat belt switch sense circuit. The driver seat belt switch cannot be repaired and, if faulty or damaged, the entire driver seat belt and retractor unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Service Precautions > Page 727 Seat Belt Buckle Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. Unplug the wire harness connector from the driver seat belt retractor. Check for continuity between the circuit cavity in the body half of the driver seat belt switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open circuit as required. 2. Check for continuity between the two cavities in the seat belt half of the driver seat belt switch wire harness 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 seat belt and retractor assembly. 3. Remove the instrument cluster from the instrument panel. Check for continuity between the seat belt switch sense circuit cavities of the instrument cluster wire harness connector (connector B) and the body half of the driver seat belt switch wire harness connector. There should be continuity. If OK, see Instrument Cluster in the Diagnosis and Testing for diagnosis of the chime request circuit. If not OK, repair the open circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Battery Temperature Sensor The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 732 Battery Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 733 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 734 Battery Temperature Sensor: Description and Operation DESCRIPTION The battery temperature sensor is attached to the battery tray located under the battery. OPERATION The battery temperature sensor 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. BATTERY TEMPERATURE SENSOR-PCM INPUT Provides a signal to the PCM corresponding to the battery temperature. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor 1. The sensor is located on the front of the battery tray. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25° C (75-80° F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 737 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. REMOVAL 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Removal/Installation. On vehicles equipped with an automatic transmission and a steering column mounted shifter an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced.. On vehicles equipped with an automatic transmission and a floor mounted shifter , a cable connects the interlock device within the steering column assembly, to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. The shifter interlock cable can be adjusted or replaced. SYSTEM DESCRIPTION The key-in ignition switch is integral to the ignition switch, which is mounted on the right side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition lock cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition lock cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 742 Ignition Switch Lock Cylinder: Service and Repair The ignition key must be in the key cylinder for cylinder removal. REMOVAL 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. Shroud Removal/Installation - Typical 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Retaining Pin 5. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 743 Flag In RUN Position Key Cylinder-Rear View Switch Mounting Screws 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 744 Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed. 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Ignition Switch View From Column Park Lock Linkage-Automatic Transmission-Typical Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 745 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkage before installing switch. Steering Wheel Lock Lever 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 3 Nm ± 0.5 Nm (26 in. lbs. ± 4 in. lbs.) torque. 11. Connect electrical connectors to ignition switch and halo lamp. Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). Tighten screws to 2 Nm (17 in. lbs.) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery. 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY; LOCK, OFF, ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify. Steering wheel should unlock when key is rotated to ON position. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Switch, park/neutral 25 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 749 Output Shaft Speed Sensor, Park/Neutral Switch, Transmission Solenoid 8-Way Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 750 Park/Neutral Position Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 751 Neutral Safety Switch: Service and Repair REMOVAL 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. INSTALLATION Fig. 19 1. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 2. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 3. Test continuity of new switch with 12V test lamp. 4. Connect switch wires and lower vehicle. 5. Top off transmission fluid level. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Overdrive Cancel Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 757 Automatic Transmission Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 758 Overdrive Switch: Description and Operation OVERDRIVE/OVERRIDE SWITCH-PCM INPUT On vehicles equipped with an automatic transmission and overdrive, the powertrain control module (PCM) regulates the 3-4 overdrive up-shift and downshift through the overdrive solenoid. This solenoid is located in the transmission. An overdrive/override push-button switch is located at the end of transmission shift lever. The overdrive/override push-button switch is normally open (overdrive allowed) when the lamp is not illuminated. It momentarily closes (overdrive not allowed) when the operator presses the switch and the lamp is illuminated. Overdrive will revert to ON (lamp off) each time the ignition switch in turned on. The transmission downshifts if the operator presses the override switch while in overdrive. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 762 Transmission Position Switch/Sensor: Description and Operation TRANSMISSION PARK/NEUTRAL SWITCH-PCM INPUT The park/neutral switch is located on the transmission housing and provides an input to the Powertrain Control Module (PCM), This will indicate that the automatic transmission is in Park, Neutral or a drive gear selection. This input is used to determine idle speed (varying with gear selection), fuel injector pulse width, ignition timing advance and vehicle speed control operation. The center terminal of the park/neutral position switch is the starter-circuit terminal. It provides the ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. The outer terminals on the switch are for the backup lamp circuit. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 763 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Transmission Speed Sensor: Specifications Sensor Mounting ................................................................................................................................. ..................................................... 27 Nm (20 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 767 Output Shaft Speed Sensor, Park/Neutral Switch, Transmission Solenoid 8-Way Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 768 Output Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input Transmission Speed Sensor: Description and Operation Output Shaft Speed Sensor-PCM Input This sensor generates a signal to the PCM relating to the speed of the transmission main drive shaft. NOTE: This input is used with 4-speed electronic transmissions only. CIRCUIT OPERATION Four Speed Automatic Transmission The output shaft speed sensor generates a signal indicating the speed of the transmission output shaft. Circuits T13 and T14 connect the sensor to the Powertrain Control Module (PCM). Circuit T13 connects to cavity B25 of the PCM. Circuit T14 connects to cavity B28. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input > Page 771 Transmission Speed Sensor: Description and Operation Sensor Operation The speed sensor is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. The vehicle speed sensor also serves as a backup for the transmission speed sensor. Signals from this sensor are shared with the powertrain control module. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 772 Transmission Speed Sensor: Service and Repair Removal Transmission Speed Sensor Removal Installation 1. Remove transmission speed sensor and O-ring seal from overdrive case. Installation 1. Install transmission speed sensor and O-ring seal in overdrive case. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 776 Transmission Temperature Sensor/Switch: Description and Operation TRANSMISSION TEMPERATURE SENSOR-PCM INPUT This input is used in the shift operation for 4-speed electronic transmissions only. The temperature data is used for: torque converter clutch operation, overdrive shift, low temperature shift compensation, wide open throttle shift strategy and governor pressure transducer calibration. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Locations 4WD Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Diagrams > 231 Transfer Case Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Diagrams > 231 Transfer Case > Page 783 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications Gear Sensor/Switch: Specifications TIGHTENING SPECIFICATIONS Switch, Indicator .................................................................................................................................. .......................................................... 15-25 ft. lbs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Specifications Rear Window Defogger Switch: Specifications Tighten the Defogger Switch mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Specifications > Page 791 Rear Window Defogger Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Specifications > Page 792 Rear Window Defogger Switch: Description and Operation SYSTEM DESCRIPTION The rear window defogger switch is integral to the rear window switch pod, which includes the rear wiper and washer switches. The rear window switch pod is installed in the instrument panel lower bezel which is located near the center of the lower instrument panel, below the heater and air conditioner controls. The rear window switch pod 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 pod cannot be repaired. If any function of the switch pod except lighting is faulty or damaged, the entire switch pod must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Specifications > Page 793 Rear Window Defogger Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. Remove the lower bezel from the instrument panel and unplug the rear window switch pod wire harness connector. 2. Check for continuity between the ground circuit cavity of the rear window switch pod 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 pod 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 pod. 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 rear window switch pod. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Specifications > Page 794 Rear Window Defogger Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. 2. Remove the lower bezel from the instrument panel. See Instrument Panel Lower Bezel/Service and Repair of Instrument Panel Systems for the procedures. Rear Window Switch Pod Remove/Install 3. Remove the two screws that secure the rear window switch pod to the instrument panel lower bezel. 4. Remove the rear window switch pod from the instrument panel lower bezel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications Power Window Switch: Specifications Power Window Motor Mounting Screws 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications > Page 798 Driver Power Window/Door Lock Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications > Page 799 Power Window Switch: Description and Operation SYSTEM OPERATION The power windows are controlled by four two-way switches and a power window lockout switch that are integral to the power window and lock switch unit on the driver side front door trim panel. Additionally, each of the passenger doors has a single gang two-way power window switch mounted in a bezel on their respective door trim panels. 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. The power window switch for the driver side front door 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 side front door power window and lock switch unit. 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 side master switch unit. When the power window lockout switch is in the Lock position, the battery feed for the individual passenger door power window switches is interrupted. The driver side power window and lock switch unit and the single gang passenger door power window switches cannot be repaired and, if faulty or damaged, the entire switch unit or switch must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications > Page 800 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, perform the diagnosis for Power Window System. 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. Unplug the wire harness connector from the switch unit. Power Window Switch Continuity - Driver Side Front Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications > Page 801 Power Window Switch Continuity - Passenger Doors 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, see Power Window Motor in the Diagnosis and Testing. If not OK, replace the faulty switch. NOTE: Because this switch contains active electronic elements for the Auto-down feature, this switch function cannot be checked with a continuity test. If the problem being diagnosed involves this function, reconnect the switch to its wire harness connector, connect the battery negative cable and turn the ignition switch to the On position. Back probe the wire harness connector cavity for switch pin number 8 and check for the proper switch output while actuating the switch. With the switch in the Up position, there should be continuity to ground at pin 8. With the switch in the Down position, there should be battery voltage at pin 8. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications > Page 802 Power Window Switch: Service and Repair REMOVAL Driver Side Front Door 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the driver side front door. 3. From the back side of the trim panel, remove the screws that secure the power window and lock switch unit to the switch bezel in the door trim panel opening. 4. Remove the power window and lock switch and the switch bezel from the door trim panel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Passenger Door 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the front or rear passenger door. 3. With a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power window switch receptacle on the back of the door trim panel switch bezel and pull the switch out of the receptacle. 4. Reverse the removal procedures to install. Be certain that both of the switch snap retainers in the receptacle on the back of the door trim panel switch bezel are fully engaged. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation Washer Fluid Level Switch: Description and Operation SYSTEM OPERATION The standard washer fluid level sensor is mounted on the inboard side and near the front of the windshield washer reservoir. A barbed nipple on the sensor is press-fit into a rubber grommet seal installed in a hole in the side of the reservoir. When the fluid level in the reservoir falls below the pivoting float on the sensor, the float changes position and closes the internal switch contacts of the sensor. Refer to Low Washer Fluid Warning Lamp in the Diagnosis and Testing of Instrument Panel Systems for diagnosis of the low washer fluid warning lamp and circuit, including the sensor. The washer fluid level sensor cannot be repaired. If faulty or damaged, the sensor unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Page 807 Washer Fluid Level Switch: Service and Repair REMOVAL AND INSTALLATION 1. Remove the washer reservoir from the engine compartment. See Washer Reservoir/Service and Repair for the procedures. NOTE: The pivoting float of the washer fluid sensor must be in a horizontal position within the reservoir in order to be removed With the reservoir empty and held in an upright position, the pivoting float will orient itself to the horizontal position when the sensor connector is pointed straight downwards. 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry the washer fluid level sensor out of the rubber grommet seal. Care must be taken not to damage the reservoir. 3. Remove the rubber grommet seal from the reservoir and discard. 4. Reverse the removal procedures to install. Always use a new rubber grommet seal on the reservoir. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications Windshield Washer Switch: Specifications Wiper/Washer Mounting Screws 20 in.lb Multi-Function Switch Wiring Harness Connector Screw 17 in.lb Multi-Function Switch Mounting Screws (2) 17 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 811 Windshield Washer Switch: Locations The windshield wiper and washer switches are contained in the multi-function switch assembly which is secured to the left side of the steering column. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 812 Multi-Function Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 813 Windshield Washer Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AN AIR-BAG, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 814 Windshield Washer Switch: Description and Operation SYSTEM OPERATION Front Multi-Function Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay, or depressed toward the steering column to activate the washer system. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained in this addresses only the switch functions for the windshield wiper and washer systems. For information relative to the other switch functions. However, the multi-function switch cannot be repaired. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Rear The single two-function rear wiper and washer switch is integral to the rear window switch pod, which includes the rear window defogger switch. The rear window switch pod is installed in the instrument panel lower bezel, which is located near the center of the lower instrument panel, below the heater and air conditioner controls. The rear wiper and washer switch controls the rear wiper and washer functions. The rear window switch pod 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 sliding-type switch features a detent in the On position for the rear wiper. Pushing in on the rear wiper switch button activates the momentary rear washer switch. The rear wiper and washer switch also has an integral illumination lamp with a serviceable bulb. Both the rear wiper and rear washer motors will operate continuously for as long as the switch is held in the momentary Wash position. The rear wiper and washer switch cannot be repaired and, if faulty or damaged, the entire rear window switch pod must be replaced. Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module and an illuminated entry module into a single unit. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 815 allows the addition of many new feature capabilities. Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-afterwash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermittent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. Refer to Central Timer module/Service and Repair of Instrument Panel Systems for the service procedures. See Wiper System Testing and Inspection for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 816 Windshield Washer Switch: Testing and Inspection Front See Wiper System and/or Washer System Testing and Inspection before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AN AIR-BAG, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. Unplug the multi-function switch wire harness connector from the multi-function switch. Multi-Function Switch Continuity 3. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 4. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required. Rear Perform the diagnosis for the rear wiper system and/or washer system as described before testing the rear wiper and washer switch. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the lower bezel from the instrument panel and unplug the rear window switch pod wire harness connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 817 Rear Wiper Switch And Washer Switch Continuity 2. Using an ohmmeter, check the rear wiper and washer switch continuity at the rear window switch pod terminals as shown in the Rear Wiper Switch and Washer Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty rear window switch pod. If the switch is OK, repair the rear wiper system and/or washer system wire harness circuits as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 818 Windshield Washer Switch: Service and Repair REMOVAL AND INSTALLATION Front WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multifunction Switch 5. Move the upper fixed column shroud far enough to access the rear of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the switch away from the steering column far enough to access and remove the multifunction switch wire harness connector screw. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: Multi-function switch wire harness connector screw -2 Nm (17 in. lbs.) - Multi-function switch mounting screws - 2 Nm (17 in. lbs.). Rear Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 819 WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. 2. Remove the lower bezel from the instrument panel. Refer to Instrument Panel Lower Bezel/Service and Repair of Instrument Panel Systems for the procedures. Rear Window Switch Pod Remove/Install 3. Remove the two screws that secure the rear window switch pod to the instrument panel lower bezel. 4. Remove the rear window switch pod from the instrument panel lower bezel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications Wiper Switch: Specifications Tighten the fasteners as follows: Multi-function switch wire harness connector screw 2 Nm (17 in. lbs.) Multi-function switch mounting screws 2 Nm (17 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 823 Wiper Switch: Locations The windshield wiper and washer switches are contained in the multi-function switch assembly which is secured to the left side of the steering column. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 824 Multi-Function Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 825 Wiper Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AN AIR-BAG, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 826 Wiper Switch: Description and Operation SYSTEM OPERATION Front Multi-Function Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay, or depressed toward the steering column to activate the washer system. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information addresses only the switch functions for the windshield wiper and washer systems. However, the multi-function switch cannot be repaired. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Rear The single two-function rear wiper and washer switch is integral to the rear window switch pod, which includes the rear window defogger switch. The rear window switch pod is installed in the instrument panel lower bezel, which is located near the center of the lower instrument panel, below the heater and air conditioner controls. The rear wiper and washer switch controls the rear wiper and washer functions. The rear window switch pod 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 sliding-type switch features a detent in the On position for the rear wiper. Pushing in on the rear wiper switch button activates the momentary rear washer switch. The rear wiper and washer switch also has an integral illumination lamp with a serviceable bulb. Both the rear wiper and rear washer motors will operate continuously for as long as the switch is held in the momentary Wash position. The rear wiper and washer switch cannot be repaired and, if faulty or damaged, the entire rear window switch pod must be replaced. Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module and an illuminated entry module into a single unit. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 827 Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-afterwash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermittent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the service procedures. See Wiper System Testing and Inspection for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 828 Wiper Switch: Testing and Inspection Front See Wiper System and/or Washer System Testing and Inspection before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AN AIR-BAG, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. Unplug the multi-function switch wire harness connector from the multi-function switch. Multi-Function Switch Continuity 3. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 4. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required. Rear Perform the diagnosis for the rear wiper system and/or washer system as described before testing the rear wiper and washer switch. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the lower bezel from the instrument panel and unplug the rear window switch pod wire harness connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 829 Rear Wiper Switch And Washer Switch Continuity 2. Using an ohmmeter, check the rear wiper and washer switch continuity at the rear window switch pod terminals as shown in the Rear Wiper Switch and Washer Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty rear window switch pod. If the switch is OK, repair the rear wiper system and/or washer system wire harness circuits as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 830 Wiper Switch: Service and Repair REMOVAL AND INSTALLATION Front WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multifunction Switch 5. Move the upper fixed column shroud far enough to access the rear of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the switch away from the steering column far enough to access and remove the multifunction switch wire harness connector screw. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: a. Multi-function switch wire harness connector screw - 2 Nm (17 in. lbs.) b. Multi-function switch mounting screws - 2 Nm (17 in. lbs.). Rear Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 831 WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. 2. Remove the lower bezel from the instrument panel. Refer to Instrument Panel Lower Bezel/Service and Repair of Instrument Panel Systems for the procedures. Rear Window Switch Pod Remove/Install 3. Remove the two screws that secure the rear window switch pod to the instrument panel lower bezel. 4. Remove the rear window switch pod from the instrument panel lower bezel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Specification Revisions Alignment: Technical Service Bulletins Steering/Suspension - Alignment Specification Revisions NUMBER: 26-12-98D GROUP: Miscellaneous DATE: December, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1999 Durango Service Manual - Publication Number 81-370-9116 DESCRIPTION OF CHANGES Revision to the wheel alignment specifications Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Specification Revisions > Page 837 2-4 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Specification Revisions > Page 838 Alignment: Technical Service Bulletins Alignment - Specification Correction NO: 02-11-98 GROUP: Suspension DATE: Oct. 30, 1998 SUBJECT: Alignment Specifications MODELS: 1999 (AN) Dakota 1999 (DN) Durango DISCUSSION: The alignment specifications identified in the 1999 Dakota Service Manual (Publication No. 81-370-9110), page 2-4 and in the 1999 Durango Service Manual (Publication No. 81-370-9116), page 2-4 have been changed. The charts identify the revised alignment specifications. In addition, the charts also identify the alignment specifications for the Dakota R/T. All changes to the Service Manual Alignment Specifications are highlighted with **Asterisks**. The specifications listed in the 1999 Dakota and Durango Service Manuals should no longer be used. Service Manual revision pages for the new alignment specifications will be available soon. Please make a note in these publications to refer to this Technical Service Bulletin until the revised pages Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Specification Revisions > Page 839 are available. POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 840 Alignment: Specifications The content of this article reflects changes called for in TSB 26-12-98. CASTER: Individual Side ..................................................................................................................................... ......................................................... +3.31° ± 1.0° Max RH/LH Difference ........................................ ..................................................................................................................................................... 0.50° CAMBER: Individual Side ..................................................................................................................................... ....................................................... +0.38° ± 0.50° Max RH/LH Difference ........................................ ..................................................................................................................................................... 0.50° TOTAL TOE: Individual Side ..................................................................................................................................... ....................................................... +0.10° ± 0.10° Max RH/LH Difference ........................................ .......................................................................................................................................................... 0° THRUST ANGLE: Standard .............................................................................................................................................. ................................................................. 0° ± 0.4° NOTE: All alignment specifications are in degrees. NOTE: For ride height adjustment and specifications see Service and Repair / Suspension Height. See: Service and Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 841 Alignment: Description and Operation Wheel Alignment Measurements 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. 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 toe 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. 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. Refer to Maintenance for the recommended maintenance schedule. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 842 Suspension And Steering System Diagnosis - Part 1 Of 2 Suspension And Steering System Diagnosis - Part 2 Of 2 SUSPENSION AND STEERING SYSTEM DIAGNOSIS Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 843 Alignment: Testing and Inspection Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart for additional information. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Suspension Height Alignment: Service and Repair Suspension Height 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. HEIGHT MEASUREMENT 1. Jounce the front of the vehicle. Height Measurements 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). HEIGHT ADJUSTMENT 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Suspension Height > Page 846 Alignment: Service and Repair Wheel Alignment CAMBER AND CASTER ADJUSTMENT Caster & Camber Adjustment-Typical Camber and caster angle adjustments involve changing the position of the upper suspension arm pivot bar. 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. The caster angle should be adjusted to preferred specification. NOTE: 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. CAMBER Move the front of the pivot bar in or out. This will change the camber angle significantly and caster angle slightly. The camber angle should be adjusted to preferred specification. After adjustment is made tighten the pivot bar nuts to proper torque specification. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Suspension Height > Page 847 Toe Adjustment 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.). 5. Verify the specifications 6. Turn off engine. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Testing Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle ......................................................................................................................... ......................................................... 500 to 900 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 856 Idle Speed: Testing and Inspection The following test procedure has been developed to check throttle body calibrations for correct idle conditions. The procedure should be used to diagnose the throttle body for conditions that may cause idle problems. This procedure should be used only after normal diagnostic procedures have failed to produce results that indicate a throttle body related problem. Be sure to check for proper operation of the idle air control motor before performing this test. Fixed Orifice Tool A special fixed orifice tool (number 6714) must be used for the following test. 1. Start the engine and bring to operating temperature. Be sure all accessories are off before performing this test. 2. Shut off the engine and remove the air duct at throttle body. Install Orifice Tool 3. Disconnect the vacuum line at the PCV valve. 4. Install the 0.185 inch orifice tool (number 6714) into the disconnected vacuum line in place of the PCV valve. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 857 Idle Purge Line 5. Disconnect the idle purge vacuum line from fitting at throttle body. This vacuum line is located on the front of throttle body next to the MAP sensor. Cap the fitting at throttle body after vacuum line has been removed. 6. Connect the DRB scan tool to the 16-way data link connector. This connector is located under the instrument panel to the left of the steering column. Refer to the appropriate Powertrain Diagnostic Procedures service for DRB operation. 7. Start the engine and allow to warm up. 8. Using the DRB scan tool, scroll through the menus as follows: select-Stand Alone DRB III, select 1999 Diagnostics, select-Engine, select-System Test, select-Minimum Air Flow. 9. The DRB scan tool will count down to stabilize the idle rpm and display the minimum air flow idle rpm. The idle rpm should be between 500 and 900 rpm. If the idle speed is outside of these specifications, replace the throttle body. Refer to Throttle Body in the Component Removal/Installation. 10. Disconnect the DRB scan tool from the vehicle. 11. Remove cap from idle purge fitting at throttle body and install vacuum line. 12. Remove orifice tool and connect vacuum line to PCV valve. 13. Install air duct to throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Air Cleaner Housing Assembly 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 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Use following procedure if fuel rail is or is not equipped with fuel pressure test port. 1. Remove fuel fill cap. 2. The fuel filler tube contains a spring-loaded flap (door) located below fuel fill cap. The flap is used as a secondary way of sealing fuel tank if fuel fill cap has not been properly tightened. It is part of EVAP monitor system when vehicle is equipped with a Leak Detection Pump (LDP). The vehicle may be equipped with flap installed into fuel filler tube even though vehicle is not equipped with LDP and EVAP monitor system. Place a nonmetallic object into fuel fill tube and press on flap to relieve any tank pressure. 3. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. 6. 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. 7. Unplug connector from any injector. 8. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 9. Connect other end of jumper wire to positive side of battery. 10. 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. 11. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 12. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 13. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 14. Return fuel pump relay to PDC. 15. 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. Refer to Emission Control System. See On-Board Diagnostics. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 881 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 882 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 883 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 884 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 885 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 886 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 892 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 893 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 894 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 895 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 896 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 897 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 898 Ignition Cable: Specifications Spark Plug Cable Resistance Minimum 250 ohms 3000 ohms Maximum 1000 ohms 12000 ohms Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 899 Ignition Cable: Description and Operation Spark plug cables are sometimes referred to as secondary ignition wires. These cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 900 Ignition Cable: Testing and Inspection Check the spark plug cable connections for good contact at the coil(s), distributor cap towers, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, distributor and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean high voltage ignition cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. Head Shields On all engines, spark plug cable heat shields are pressed into the cylinder head to surround each spark plug cable boot and spark plug. These shields protect the spark plug boots from damage (due to intense engine heat generated by the exhaust manifolds) and should not be removed. After the spark plug cable has been installed, the lip of the cable boot should have a small air gap to the top of the heat shield. Testing When testing secondary cables for damage with an oscilloscope, follow the instructions of the equipment manufacturer. If an oscilloscope is not available, spark plug cables may be tested as follows: CAUTION: Do not leave any one spark plug cable disconnected for longer than necessary during testing. This may cause possible heat damage to the catalytic converter. Total test time must not exceed ten minutes. With the engine running, remove spark plug cable from spark plug (one at a time) and hold next to a good engine ground. If the cable and spark plug are in good condition, the engine rpm should drop and the engine will run poorly. If engine rpm does not drop, the cable and/or spark plug may not be operating properly and should be replaced. Also check engine cylinder compression. With the engine not running, connect one end of a test probe to a good ground. Start the engine and run the other end of the test probe along the entire length of all spark plug cables. If cables are cracked or punctured, there will be a noticeable spark jump from the damaged area to the test probe. The cable running from the ignition coil to the distributor cap can be checked in the same manner. Cracked, damaged or faulty cables should be replaced with resistance type cable. This can be identified by the words ELECTRONIC SUPPRESSION printed on the cable jacket. Use an ohmmeter to test for open circuits, excessive resistance or loose terminals. If equipped, remove the distributor cap from the distributor. Do not remove cables from cap. Remove cable from spark plug. Connect ohmmeter to spark plug terminal end of cable and to corresponding electrode in distributor cap. Resistance should be 250 to 1000 Ohms per inch of cable. If not, remove cable from distributor cap tower and connect ohmmeter to the terminal ends of cable. If resistance is not within specifications as found in the SPARK PLUG CABLE RESISTANCE chart, replace the cable. Test all spark plug cables in this manner. SPARK PLUG CABLE RESISTANCE MINIMUM = MAXIMUM 250 Ohms Per Inch = 1000 Ohms Per Inch 3000 Ohms Per Foot = 12,000 Ohms Per Foot Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 901 Ignition Cable: Service and Repair REMOVAL AND INSTALLATION Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. Engine Firing Order Install cables into the proper engine cylinder firing order. When replacing the spark plug and coil cables, route the cables correctly and secure in the proper retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause cross ignition of the plugs or short circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and the distributor cap tower. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Cap Inspection - External - Typical Cap Inspection-Internal-Typical Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the inside (caused by condensation entering the cap through cracks). Replace any cap that displays charred or eroded terminals. The machined surface of a terminal end (faces toward rotor) will indicate some evidence of erosion from normal operation. Examine the terminal ends for evidence of mechanical interference with the rotor tip. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Rotor Inspection - Typical Visually inspect the rotor for cracks, evidence of corrosion or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on the end of the metal tip. The silicone-dielectric- varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap 0.040 in Torque 30 ft lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 912 Spark Plug: Application and ID Plug Type ............................................................................................................................................ .................................................................... RC12LC4 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 913 Spark Plug: Description and Operation All engines use resistor type spark plugs. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Spark plugs that have low milage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Refer to the Spark Plug Condition. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 914 Spark Plug: Testing and Inspection SPARK PLUG CONDITIONS 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. Gap growth will not average more than approximately 0.025 mm (0.001 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. Oil Or Ash Encrusted Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 915 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. 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. Scavenger Deposits Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but this is a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy, but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and can be cleaned using standard procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 916 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. 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.) Spark Plug Overheating Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 917 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 918 Spark Plug: Service and Repair Heat Shields On all engines, spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. PLUG REMOVAL Cable Removal 1. Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result. 2. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. This will help prevent foreign material from entering the combustion chamber. 3. Remove the spark plug using a quality socket with a rubber or foam insert. 4. Inspect the spark plug condition. Refer to Spark Plug Condition in the Diagnostics and Testing. PLUG CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. PLUG GAP ADJUSTMENT Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 919 Setting Spark Plug Gap - Typical Check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode. Never attempt to adjust the gap by bending the center electrode. SPARK PLUG GAP 1.01 mm (0.040 in) PLUG INSTALLATION Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 35-41 Nm (26-30 ft. lbs.) torque. 3. Install spark plug cables over spark plugs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression should not be less than 689 kPa (100 psi) and not vary more than 172 kPa (25 psi) from cylinder to cylinder. If cylinder(s) have abnormally low compression pressures, repeat procedure. - If the same cylinder(s) repeat an abnormally low reading, it could indicate the existence of a problem in the cylinder. NOTE: The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should NOT be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 923 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST 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. (Refer to Powertrain Management for the correct procedure) 5. Disconnect the ignition coil. 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. Refer to Engine Specifications for the correct engine compression pressures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all times. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection Drive Belt: Testing and Inspection VISUAL DIAGNOSIS Belt Wear Patterns When diagnosing serpentine accessory drive belts small cracks that run across the ribbed surface of the belt from rib to rib, 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. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer to the Accessory Drive Belt Diagnosis charts 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 930 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 931 ACCESSORY DRIVE BELT DIAGNOSIS CHART Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 932 Drive Belt: Service and Repair REMOVAL Automatic Belt Tensioner-Belt Removal/Installation Drive belts these engines are equipped with a spring loaded automatic belt tensioner. This belt tensioner will be used on all belt configurations, such as with or without power steering or air conditioning. For more information, refer to Drive Belts, Mounts, Brackets and Accessories. 1. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 2. Rotate tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. 3. Remove belt from idler pulley first. 4. Remove belt from vehicle. INSTALLATION CAUTION: When installing serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. For correct 3.9L/ 5.2L/ 5.9L engine belt routing. The correct belt with correct length must be used. 1. Position drive belt over all pulleys except idler pulley. This pulley is located between generator and A/C compressor. 2. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 3. Rotate socket/wrench clockwise. Place belt over idler pulley. Let tensioner rotate back into place. Remove wrench. Be sure belt is properly seated on all pulleys. 4. Check belt indexing marks. Refer to the proceeding Automatic Belt Tensioner-3.9L/5.2L/5.9L Engine for more belt information. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 933 Automatic Belt Tensioner/Pulley Assembly-3.9L/5.2L/5.9L Engine The tensioner is equipped with an indexing arrow on back of tensioner and an indexing mark on tensioner housing. If a new belt is being installed, arrow must be within approximately 3 mm (1/8 in.) of indexing mark (Point B-. Belt is considered new if it has been used 15 minutes or less. If this 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 Routing-3.9L/5.2L/5.9L Engine ^ Belt incorrectly routed. A used belt should be replaced if tensioner indexing arrow has moved beyond point A. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Air Cleaner Housing Assembly 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 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications Fluid Filter - A/T: Specifications Screws, fluid filter 35 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Use following procedure if fuel rail is or is not equipped with fuel pressure test port. 1. Remove fuel fill cap. 2. The fuel filler tube contains a spring-loaded flap (door) located below fuel fill cap. The flap is used as a secondary way of sealing fuel tank if fuel fill cap has not been properly tightened. It is part of EVAP monitor system when vehicle is equipped with a Leak Detection Pump (LDP). The vehicle may be equipped with flap installed into fuel filler tube even though vehicle is not equipped with LDP and EVAP monitor system. Place a nonmetallic object into fuel fill tube and press on flap to relieve any tank pressure. 3. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. 6. 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. 7. Unplug connector from any injector. 8. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 9. Connect other end of jumper wire to positive side of battery. 10. 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. 11. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 12. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 13. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 14. Return fuel pump relay to PDC. 15. 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. Refer to Emission Control System. See On-Board Diagnostics. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Locations Fuel Pump Pickup Filter: Locations Fuel Pump Inlet Filter The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Locations > Page 949 Fuel Pump Pickup Filter: Description and Operation FUEL PUMP MODULE Fuel Pump Module/Fuel Tank (Top View) Fuel Pump Module Components (Typical Pump Module Shown) The fuel pump module on all models/all engines is installed in the top of the fuel tank. The fuel pump module contains the following components. A combination fuel filter/fuel pressure regulator - Electric fuel pump - Fuel pump reservoir - A separate in-tank fuel filter (at bottom of module) - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection at filter/regulator - A metal lock-ring to retain pump module to fuel tank - A gasket between tank flange and module The fuel gauge sending unit (fuel level sensor), and pick-up filter (at bottom of module) may be serviced separately. If the electrical fuel pump requires service, the entire fuel pump module must be replaced. The fuel filter/fuel pressure regulator may be serviced separately. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Service and Repair > Fuel Pump Inlet Filter Replacement Fuel Pump Pickup Filter: Service and Repair Fuel Pump Inlet Filter Replacement Fuel Pump Inlet Filter 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. REMOVAL 1. Remove fuel tank. Refer to Fuel Tank Removal/ Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/installation, 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 1. Snap new filter to bottom of module. Be sure O-ring is in correct position. 2. Install fuel pump module. Refer to Fuel Pump Module Removal/installation. 3. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Service and Repair > Fuel Pump Inlet Filter Replacement > Page 952 Fuel Pump Pickup Filter: Service and Repair Fuel Pump Module Replacement REMOVAL WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING FUEL PUMP MODULE, FUEL SYSTEM PRESSURE MUST BE RELEASED. The fuel pump module is located in top of fuel tank. 1. Drain fuel tank and remove tank. Refer to Fuel Tank Removal/lnstallation. 2. Thoroughly wash and clean area around pump module to prevent contaminants from entering tank. Fuel Pump Module And Locking 3. Part of Fuel Tank Removal Procedure: Disconnect EVAP line at pump module; disconnect wiring harness connector at pump module; disconnect fuel line from fuel filter fitting. 4. Rotate fuel filter until its fitting is pointed towards center of pump module. 5. A metal lockring is used to secure fuel pump module to fuel tank. Six metal fingers are molded into the plastic fuel tank. The fingers are used to retain lockring to fuel tank. A rubber gasket is used as a seal between module and fuel tank. 6. Before removing lockring, apply a small amount of engine oil to 6 fingers where fingers meet lockring (to act as a lubricant). 7. Remove (rotate) lockring counterclockwise using a brass or bronze drift punch and a hammer. This must be done while slightly prying back on lock tab. 8. Remove lockring and pump module from fuel tank. INSTALLATION CAUTION: Whenever fuel pump module is serviced, the module gasket must be replaced. 1. Using a new gasket, position fuel pump module into opening in fuel tank. Be sure rubber gasket remains in place. Rotate pump module assembly until module is positioned as shown in. This step must be followed to prevent float/float rod from contacting sides of fuel tank. 2. Before installing lockring, apply a small amount of engine oil to 6 fingers where fingers meet lockring (to act as a lubricant). 3. Position lockring over top of fuel pump module. Tighten finger tight. 4. Install (rotate) lockring clockwise using a brass or bronze drift punch and a hammer. Continue rotating lockring until 6 fingers drop into 6 finger locks and lock tab falls into lockring notch. 5. Install fuel tank. Refer to Fuel Tank Installation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair Oil Filter: Service and Repair FILTER SPECIFICATION All engines are equipped with a high quality full flow, disposable type oil filter. Chrysler Corporation recommends a Mopar(R) or equivalent oil filter be used. OIL FILTER REMOVAL 1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench loosen filter. Oil Filter Removal-Typical 3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss. 4. when filter separates from adapter nipple, tip gasket end upward to minimize oil spill. Remove filter from vehicle. Oil Filter Sealing Surface-Typical 5. With a wiping cloth, clean the gasket sealing surface of oil and grime. OIL FILTER INSTALLATION 1. Lightly lubricate oil filter gasket with engine oil or chassis grease. 2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Specifications Refrigerant Filter: Specifications Tighten the front liquid line block mounting screw to 13.5 Nm (120 in. lbs.). Tighten the filter drier bracket mounting screw to 6.8 Nm (60 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Specifications > Page 959 Refrigerant Filter: Locations Filter-Drier Remove/Install 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Specifications > Page 960 Refrigerant Filter: Description and Operation SYSTEM DESCRIPTION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Specifications > Page 961 Refrigerant Filter: Service and Repair WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Filter-Drier Remove/Install 3. Remove the screws that secure the front and rear liquid line block fittings to the filter-drier inlet and outlet. Disengage the block fittings from the filter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Remove the screw that secures the filter-drier mounting bracket to the front fender wheelhouse front extension. 5. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Description and Operation Coolant Line/Hose: Description and Operation COOLING SYSTEM HOSES AND CLAMPS Radiator lower hoses are spring-reinforced to prevent collapse from water pump suction at moderate and high engine speeds. Inspect hoses at regular intervals. Replace hoses that are cracked, feel brittle when squeezed, or swell excessively when system is pressurized. The use of molded replacement hoses is recommended. When performing a hose inspection, inspect radiator lower hose for proper position and condition of spring. Hose Clamp Tool-Typical 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. Clamp Number/Letter Location 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > A/C Discharge Hose/Line Hose/Line HVAC: Specifications Refrigerant Line Mounting Screws 20 in.lb B-Pillar Refrigerant Line Mounting Nuts 100 in.lb B-Pillar Refrigerant Line Clamp Mounting Screws 20 in.lb B-Pillar Refrigerant Line Mounting Screw 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > A/C Discharge Hose/Line > Page 970 Hose/Line HVAC: Specifications Front Liquid Line Block Fitting to Filter-Drier Inlet Mounting Screw 120 in.lb Rear Liquid Line Block Fitting to Expansion Valve Stud Mounting Nut 200 in.lb Rear Liquid Line Block Fitting to Filter-Drier Outlet Mounting Screw 120 in.lb Ground Strap to Inboard Side of Rear Liquid Line Block Mounting Screw 60 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > A/C Discharge Hose/Line > Page 971 Hose/Line HVAC: Specifications Refrigerant Line Manifold Mounting Screw 200 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Locations > A/C Discharge Hose/Line Suction And Discharge Line Remove/Install - Typical Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Locations > A/C Discharge Hose/Line > Page 974 B-Pillar Refrigerant Lines Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Locations > A/C Discharge Hose/Line > Page 975 Suction And Discharge Line Remove/Install - Typical Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Locations > Page 976 Hose/Line HVAC: Description and Operation SYSTEM DESCRIPTION Refrigerant Line 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 inner hose liner is used for the R-134a air conditioning system on this vehicle. This nylon liner 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 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 status 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. Low Pressure Gauge Hose The low pressure hose (Blue with Black stripe) attaches to the suction service port. This port is located on the compressor manifold, directly over the suction port of the compressor. High Pressure Gauge Hose The high pressure hose (Red with Black stripe) attaches to the discharge service port. This port is located on the liquid line between the condenser and the evaporator, near the front of the engine compartment. Recovery/Recycling/Evacuation/Charging Hose The center manifold hose (Yellow, or White, with Black stripe) is used to recover, evacuate, and charge the refrigerant system. When the low or high pressure valves on the manifold gauge set are opened, the refrigerant in the system will escape through this hose. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 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. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery 3. Unplug the wire harness connector from the high pressure cut-off switch. 4. Disconnect the refrigerant line couplers at the condenser and the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the nut that secures the refrigerant line support bracket near the compressor. Suction And Discharge Line Remove/Install - Typical 6. 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. 7. Remove the suction and discharge line assembly from the vehicle. INSTALLATION 1. Remove the tape or plugs from all of the refrigerant line fittings. Install the refrigerant line couplers to the condenser and the suction line jumper. 2. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 Nm (200 in. lbs.). 3. Install the nut that secures the refrigerant line support bracket near the compressor. 4. Plug in the wire harness connector to the high pressure cut-off switch. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, Evacuating the A/C System, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 7. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, A/C System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 979 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement 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. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. FRONT REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery Liquid Line Remove/Install 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. INSTALLATION 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. Connect the battery negative cable. 4. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, Evacuating the A/C System, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 5. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, A/C System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge REAR REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 980 3. Remove the engine air filter housing. 4. Remove the nut that secures the ground strap to the inboard side of the rear liquid line block fitting. 5. Remove the screw that secures the rear liquid line block fitting to the outlet 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. 6. Disconnect the suction line from the suction jumper. 7. If the vehicle is equipped with the optional rear overhead A/C unit, disconnect the refrigerant line couplers near the dash panel between the suction line jumper and the rear liquid line extension and both of the underbody refrigerant lines. Install plugs in, or tape over all of the opened refrigerant line fittings. 8. Disengage the clip that secures the rear liquid line to the inner fender shield. 9. Remove the nut that secures the rear liquid line block fitting to the stud on the expansion valve, and disengage the fitting from the expansion valve. Install plugs in, or tape over all of the opened refrigerant line fittings. 10. Remove the rear liquid line from the engine compartment. 11. Remove the suction line jumper from the rear liquid line block fitting. INSTALLATION 1. Install the suction line jumper into the rear liquid line block fitting. 2. Remove the tape or plugs from the rear liquid line block fitting and the expansion valve. Install the rear liquid line block fitting over the expansion valve stud and secure the connection with a nut. Tighten the mounting nut to 22.5 Nm (200 in. lbs.). 3. Install the rear liquid line in the clip on the inner fender shield. 4. If the vehicle is equipped with the optional rear overhead A/C unit, remove the tape or plugs from the refrigerant line fittings on the suction line jumper and the rear liquid line extension and both of the underbody refrigerant lines. Connect the underbody refrigerant lines to the suction line jumper and the rear liquid line extension. 5. 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.). Connect the suction line from the suction discharge assembly to the suction jumper tube. 6. Reinstall the nut that secures the ground strap to the inboard side of the rear liquid line block fitting. Tighten the mounting screw to 6.8 Nm (60 in. lbs.). 7. Reinstall the engine air filter housing. 8. Connect the battery negative cable. 9. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, Evacuating the A/C System, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 10. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, A/C System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 981 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement Suction and Discharge 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. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery 3. Unplug the wire harness connector from the high pressure cut-off switch. 4. Disconnect the refrigerant line couplers at the condenser and the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the nut that secures the refrigerant line support bracket near the compressor. Suction And Discharge Line Remove/Install - Typical 6. 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. 7. Remove the suction and discharge line assembly from the vehicle. INSTALLATION 1. Remove the tape or plugs from all of the refrigerant line fittings. Install the refrigerant line couplers to the condenser and the suction line jumper. 2. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 Nm (200 in. lbs.). 3. Install the nut that secures the refrigerant line support bracket near the compressor. 4. Plug in the wire harness connector to the high pressure cut-off switch. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, Evacuating the A/C System, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 7. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, A/C System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 982 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. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 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, Service and Repair, Refrigerant Recovery, See: Heating and Air Conditioning/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 rear 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 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, Service and Repair, Refrigerant System Evacuate, Evacuating the A/C System, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 8. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, A/C System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 983 Hose/Line HVAC: Service and Repair B-Pillar Refrigerant Line Replacement The B-pillar refrigerant lines are used only on models with the optional rear overhead A/C unit. Both the B-pillar suction line and the B-pillar liquid line are available for separate service replacement. Each line may be removed independently from the vehicle for service. 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. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery 3. Raise and support the vehicle. 4. From under the vehicle, disconnect the underbody liquid line refrigerant line coupler at the B-pillar liquid line and the underbody suction line refrigerant line coupler at the B-pillar suction line. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Lower the vehicle. 6. Remove the headliner from the passenger compartment of the vehicle. Rear Overhead A/C Unit Refrigerant Line Remove/Install 7. From the passenger compartment, remove the fasteners that secure the block fittings at the top of the B-pillar refrigerant lines to the rear overhead A/C unit (nut from stud - liquid line) (nut and bolt suction line), and disengage the fittings. Install plugs in, or tape over all of the opened refrigerant line fittings. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 984 B-Pillar Refrigerant Lines Remove/Install 8. Remove the two screws that secure the B-pillar refrigerant line clamps to the B-pillar. 9. Remove the two screws that secure the B-pillar refrigerant line clamp and seal unit to the floor panel at the base of the B-pillar. 10. Tilt the top of the B-pillar refrigerant line unit towards the front of the vehicle far enough so that the tower end of the unit can be lifted out through the hole in the floor panel. 11. Remove the B-pillar refrigerant line unit from the passenger compartment. NOTE: If either the liquid line or the suction line is removed from the B-pillar refrigerant line clamp and seal, the clamp and seal will be damaged. Replace the clamp and seal with a new unit. INSTALLATION 1. Position the B-pillar refrigerant line unit in the passenger compartment with the lower end of the lines inserted through the hole in the floor panel at the base of the B-pillar, and the top end of the lines oriented towards the front of the vehicle. 2. Tilt the top of the B-pillar refrigerant line unit up into position near the rear overhead A/C unit. 3. Remove the tape or plugs from block fittings at the top of the B-pillar refrigerant line unit, and from the fittings on the rear overhead A/C unit. Install the B-pillar refrigerant line block fittings over the one stud on the rear overhead A/C unit. Install the bolt holding the suction line, and secure the connections with the mounting nuts. Tighten the mounting nuts to 11.3 Nm (100 in. lbs.). 4. Position the B-pillar refrigerant line clamp and seal over the hole in the floor panel and secure it with two screws. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 5. Position the B-pillar refrigerant line over the mounting holes in the inner B-pillar and secure with a screw. Tighten the mounting screw to 2.2 Nm (20 in. lbs.). 6. Reinstall the headliner in the passenger compartment. 7. Raise and support the vehicle. 8. From under the vehicle, remove the tape or plugs from the refrigerant line fittings at the underbody and B-pillar liquid lines, and from the underbody and B-pillar suction lines. Connect the underbody refrigerant lines to the B-pillar refrigerant lines. 9. Connect the battery negative cable. 10. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair. Refrigerant System Evacuate, Evacuating the A/C System, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 11. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, A/C System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 985 Hose/Line HVAC: Service and Repair Underbody Refrigerant Line Replacement The underbody refrigerant lines are used only on models with the optional rear overhead A/C unit. Both the underbody suction line and the underbody liquid line are available for separate service replacement, and may be removed from the vehicle independently for service. 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. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery Underbody Refrigerant Line Remove/Install 3. From the engine compartment, disconnect the underbody liquid line refrigerant line coupler at the liquid line extension and the underbody suction line refrigerant line coupler at the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Raise and support the vehicle. 5. From under the vehicle, disconnect the underbody liquid line refrigerant line coupler at the B-pillar liquid line and the underbody suction line refrigerant line coupler at the B-pillar suction line. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Remove the screws that secure the three underbody refrigerant line clamps to the underbody. 7. Remove the underbody refrigerant line unit from the vehicle. INSTALLATION 1. From under the vehicle, position the underbody refrigerant line unit to the underbody and secure the refrigerant line clamps with the mounting screws in three places. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 2. Remove the tape or plugs from the refrigerant line fittings at the rear of the underbody liquid and suction lines and at the B-pillar liquid and suction lines. Connect the underbody refrigerant lines to the B-pillar refrigerant lines. 3. Lower the vehicle. 4. From the engine compartment, remove the tape or plugs from the refrigerant line fittings at the front of the underbody liquid and suction lines and at the liquid line extension and the suction line jumper. Connect the underbody refrigerant lines to the engine compartment refrigerant lines. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, Evacuating the A/C System, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 7. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, A/C System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Pressure Line ...................................................................................................................................... ...................................................... 35 Nm (25 ft. lbs.) Return Line ..................................................... .......................................................................................................................................... 35 Nm (25 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 993 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 994 Brake Fluid: Testing and Inspection CAUTION: The hydraulic fluid used in automotive brake systems is hygroscopic. This means that the hydraulic fluid tends to absorb moisture from the atmosphere over periods of time. As hydraulic brake fluid absorbs moisture, it effects the function of the vehicles hydraulic brake system. For this reason, the vehicle's hydraulic brake fluid should be drained and replaced using fresh clean hydraulic brake fluid every two years. When replacing hydraulic brake fluid, use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications. BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates 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 the fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber parts or components containing rubber coming into contact with the brake fluid. This includes the master cylinder, proportioning valves, caliper seals, wheel cylinder seals, ABS hydraulic control unit (HCU), and all hydraulic fluid hoses. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 995 Brake Fluid: Service and Repair Always clean the master cylinder reservoir and caps before checking fluid level. If not cleaned, dirt could enter the fluid. Brake Fluid Level Inspection The fluid fill level is indicated on the side of the master cylinder reservoir. The correct fluid level is to the FULL indicator on the side of the reservoir. If necessary, add fluid to the proper level. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant ................................................................................................................................................ ............................................. 13.5 liters ( 14.3 quarts) NOTES: - Nominal refill capacities are shown. A variation may be observed from vehicle to vehicle due to manufacturing tolerances and refill procedures. - Capacities shown include vehicles with air conditioning and/or heavy-duty cooling systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1000 Coolant: Fluid Type Specifications The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37° C (-35° F). The antifreeze concentration must always be a minimum of 44%, year round, in all climates. If percentage is lower than 44%, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% antifreeze concentration, which prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. 100 Percent Ethylene-Glycol Should Not Be Used Use of 100 Percent Ethylene-Glycol will cause formation of additive deposits in the system, as the corrosive inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise as high as 149° C (300° F). this temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 % ethylene-glycol freezes at 22° C (-8° F). Propylene-Glycol Formulations Should Not Be Used Propylene-glycol formulations do not meet the required specifications. It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32° C (-26° F), 5 degrees higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257° F) at 96.5 kPa (14 PSI), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can result in boil-over and freeze up. Propylene-Glycol also has a poorer heat transfer characteristics than ethylene-glycol. This can increase cylinder head temperatures under certain conditions. Propylene-Glycol/Ethylene-Glycol Mixtures Should Not Be Used Propylene-glycol/ethylene-glycol mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the coling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining the freeze point will not be accurate. Both the refractive index and specific gravity differ between the ethylene-glycol and propylene-glycol. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1001 Coolant: Service Precautions DO NOT mix green colored coolant with orange colored coolant. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1002 Coolant: Description and Operation The cooling system is designed around the coolant. Coolant flows through the engine water jacket absorbing heat produced during engine operation. The coolant carries the heat to radiator and heater core. Here it is transferred to the ambient air passing through the radiator and heater core fins. The coolant also removes heat from the automatic transmission fluid in vehicles equipped with an automatic transmission. WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT RUNNING TEMPERATURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. CAUTION: Do not use straight antifreeze as engine coolant, inadequate engine running temperatures can result. Do not operate vehicle without proper concentration of recommended ethylene glycol coolant, high running temperatures and cooling system corrosion can result. The cooling system factory fill is a mixture of 50% Ethylene Glycol based antifreeze and 50% water. Using a suitable hydrometer, measure antifreeze concentration in the radiator when the engine is cool. If the cooling system has recently been serviced, allow coolant to circulate for at least 20 minutes before taking hydrometer reading. Properly mixed coolant will protect the cooling system to -37°C (-35°F). If the freeze protection is above -28°C (-20°F), drain enough coolant from the cooling system to allow room to add antifreeze to achieve adequate protection. Chrysler Corporation recommends Mopar(R) Antifreeze/Coolant or a high quality, ethylene glycol base antifreeze/coolant, with a silicate inhibitor. COOLANT PERFORMANCE ETHYLENE-GLYCOL MIXTURES The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37°C (-35°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. 100 Percent Ethylene-Glycol-Should Not Be Used in Chrysler Vehicles Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149°C (300)°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22°C (-8°F). Propylene-glycol Formulations-Should Not Be Used in Chrysler Vehicles Propylene-glycol formulations do not meet Chrysler coolant specifications. It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32°C (-26°F) 5 °C higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propyleneglycol is 125°C (257°F) at 96.5 kPa (14 psi), compared to 128°C (263 °F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up in Chrysler vehicles, which are designed for ethylene-glycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can increase cylinder head temperatures under certain conditions. Propylene-glycol/Ethylene-glycol Mixtures-Should Not Be Used in Chrysler Vehicles Propylene-glycol/Ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene glycol. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. COOLANT SELECTION AND ADDITIVES The presence of aluminum components in the cooling system requires strict corrosion protection. Maintain coolant at specified level with a mixture of ethylene-glycol based antifreeze and water. Chrysler Corporation recommends Mopar(R) Antifreeze or equivalent. If coolant becomes contaminated or looses color, drain and flush cooling system and fill with correctly mixed solution. A 0.25 percent emulsifiable oil is added to the radiator at the factory to prevent solder corrosion. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1003 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1008 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1009 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1010 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1011 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1012 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Total Capacity ...................................................................................................................................... .............................................. 9.1-9.5L (9.6-10.0 Qt) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1015 Fluid - A/T: Fluid Type Specifications See TSB 21-010-06 4/14/2006 Mopar (R) ATF Plus 4, Type 9602 automatic transmission fluid is the recommended fluid type. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1016 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 OVERVIEW Transmission fluid level should be checked monthly under normal operation. If the vehicle is used for trailer towing or similar heavy load hauling, check fluid level and condition weekly. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. FLUID LEVEL CHECK PROCEDURE 1. Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82°C (180°F). 2. Position vehicle on level surface. 3. Start and run engine at curb idle speed. 4. Apply parking brakes. 5. Shift transmission momentarily into all gear ranges. Then shift transmission back to Neutral. 6. Clean top of filler tube and dipstick to keep dirt from entering tube. Fig. 10 7. Remove dipstick (Fig. 10) and check fluid level as follows: a. Correct acceptable level is in crosshatch area. b. Correct maximum level is to MAX arrow mark. c. Incorrect level is at or below MIN line. d. If fluid is low, add only enough MOPAR ATF+4 to restore correct level. Do not overfill. CAUTION: Do not overfill the transmission. Overfilling may cause leakage out the pump vent which can be mistaken for a pump seal leak. Overfilling will also cause fluid aeration and foaming as the excess fluid is picked up and churned by the gear train. This will significantly reduce fluid life. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 1019 Fluid - A/T: Service and Repair Fluid and Filter Replacement Refer to the Maintenance Schedules in Maintenance, for proper service intervals. The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. Fig. 11 3. Remove bolts holding front and sides of pan to transmission (Fig. 11). 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 bolt holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. Fig. 12 9. Remove screws holding filter to valve body (Fig. 12). 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used bans fluid and filter properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal or fiber contamination. A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompanied by slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts or debris, refer to Diagnosis and Testing. Check the adjustment of the front and rear bands, adjust if necessary. CLEANING Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 1020 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean gasket material from gasket surface of transmission case and the gasket flange around the pan. INSTALLATION 1. Place replacement filter in position on valve body. 2. Install screws to hold filter to valve body (Fig. 12). Tighten screws to 4 Nm (35 inch lbs.) torque. 3. Place new gasket in position on pan and install pan on transmission. 4. Place pan in position on transmission. 5. Install screws to hold pan to transmission (Fig. 11). Tighten bolts to 17 Nm (150 inch lbs.) torque. 6. Lower vehicle and fill transmission with MOPAR ATF+4, type 9602 fluid. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Differential Cover - Updated Sealer & Fluid Fluid - Differential: Technical Service Bulletins Differential Cover - Updated Sealer & Fluid NUMBER: 03-08-00 GROUP: Axle & Propeller Shaft DATE: Sep. 5, 2000 SUBJECT: RTV Use On Corporate Axle MODELS: NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH AN 8.25, 9.25, OR C205F CORPORATE AXLE. DISCUSSION: The axle lubricant used in all corporate axles was changed in formulation starting at the beginning of the 1998 model year. The corporate axles involved include: the 8.25 and 9.25 rear axles, and the C205F front axle. The new lubricant in use is SAE 75W-90 p/n 05010320AA. The lubricant change was made as a fuel economy improvement. The new axle lubricant is more chemically aggressive/reactive when in contact with the previous used Room Temperature Vulcanizable (RTV) sealant. Because of this condition, the RTV used in assembly of the pan/cover to the axle housing was revised and improved. When re-sealing axle covers, using the proper sealing material to minimize any potential sealant breakdown is important. The only recommended sealing material for all corporate axle covers is MOPAR RTV Sealant, p/n 05013477M. This RTV is red/orange in color. NOTE: IF SAE 75W-90 LUBRICANT IS USED TO REFILL ANY CORPORATE AXLE, THEN THE RED/ORANGE MOPAR RTV SEALANT, P/N 05013477AA, SHOULD BE USED TO SEAL THE COVER TO THE AXLE HOUSING. To optimize sealant performance and enhance adhesion, flanges should be clean and free of residual lubricant. The mating flanges should first be cleaned of any excess old RTV using a plastic putty knife. Final cleaning/degreasing shall be done by spraying MOPAR Brake Parts Cleaner, p/n 04549623, on the carrier and cover flanges, followed by a wipe with a clean dry cloth. Care should be taken to avoid spraying the parts cleaner inside the carrier. Once the RTV has been applied, the axle cover is to be installed to the housing within 3 to 5 minutes to prevent skinning over of the RTV. NOTE: IF THE AXLE COVER IS NOT INSTALLED WITHIN THE 3 TO 5 MINUTE TIME FRAME, THE CARRIER COVER FACE MUST BE RECLEANED AND NEW RTV APPLIED, OR ADHESION QUALITY WILL BE COMPROMISED. Immediately install the cover attaching bolts and tighten them to the specified torque to prevent a shimming effect by the RTV. POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Differential Cover - Updated Sealer & Fluid > Page 1025 Fluid - Differential: Technical Service Bulletins Differential - Fluid Discoloration Explanation NUMBER: 03-02-00 GROUP: Axles DATE: Mar.03, 2000 SUBJECT: 9.25 Axle Gear Marking Compound Causes A Milky-Like Appearance To The Axle Fluid MODELS: 1999 - 2000 (AB) Ram Van 1999 - 2000 (AN) Dakota 1999 - 2000 (BR/BE) Ram Truck 1999 - 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 9.25 INCH REAR AXLE AND BUILT BETWEEN NOV. 1, 1998 (MDH 1101XX) AND NOV. 1,1999 (MDH 1101XX). DISCUSSION: The customer or servicing technician may notice a milky-like appearance to the 9.25 inch rear axle fluid. This condition may be brought to the customer's attention when the axle fluid is inspected during normal service. Other than the concern for the color of axle fluid, the customer does not experience any other axle complaint. The customer or servicing technician may be concerned because a milky-like appearance to the axle fluid may also indicate the presence of water. The cause of the milky-like appearance to the axle fluid may be due to the use of a white color gear marking compound during the axle assembly process. Axle gear marking compound is used to verify correct ring and pinion gear alignment during manufacture. The 9.25 inch rear axle is assembled on two different assembly lines. To visually distinguish axles from each assembly line, one assembly line used a white color gear marking compound (versus yellow). Half of the axles that were assembled during the above time frame may have the white gear marking compound mixed with the rear axle fluid. The white color gear marking compound is no longer in use by the axle assembly plant. NOTE: IF THE MILKY-LIKE REAR AXLE FLUID APPEARANCE IS DUE TO THE WHITE GEAR MARKING COMPOUND, THEN NO SERVICE ACTION IS NECESSARY TO ADDRESS THIS CONDITION. If the milky-like rear axle fluid appearance is due to the presence of water, then the rear axle will require service. Axle fluid, contaminated with water, may cause rust and damage to the internal components of the axle. Any water in the axle fluid will begin to boil off (reach its gaseous state) before the oil. Placing a small sample of axle fluid on a hot steel surface (around 100C or 212F) will cause any water that may be present in the fluid to boil off with a "sizzle-like" sound. POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front Axle - 194FIA Differential Oil Capacity Lube Capacity ...................................................................................................................................... ............................................... 1.72 liters (3.60 pints) 8 1/4 Axle Differential Oil Capacity Lube Capacity ...................................................................................................................................... ................................................ 2.22 Liters (4.7 pints) Trac-lok Additive .............................................. ........................................................................................................................................ 148 ml (5 ounces) 9 1/4 Axle Differential Oil Capacity Lube Capacity ...................................................................................................................................... ................................................ 2.32 Liters (4.9 pints) Trac-lok Additive .............................................. ........................................................................................................................................ 148 ml (5 ounces) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1028 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Grade ................................................................................................................................................... ................................................................... API GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 If equipped with TRAC-LOK, include the specified amount of friction modifier. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page 1029 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Front Axle Fluid - Differential: Service and Repair Front Axle 1. Raise and support the vehicle. 2. Remove the lubricant fill hole plug from the differential housing cover. 3. Remove the differential housing cover and drain the lubricant from the housing. 4. Clean the housing cavity with a flushing oil, light engine oil or lint free cloth. Do not use water, steam, kerosene or gasoline for cleaning. 5. Remove the sealant from the housing and cover surfaces. Use solvent to clean the mating surfaces. Fig. 3 6. Apply a bead of MOPAR Silicone Rubber Sealant, or equivalent, to the housing cover. Install the housing cover within 5 minutes after applying the sealant. 7. Install the cover and any identification tag. Tighten the cover bolts in a cries-cross pattern to 41 Nm (30 ft. lbs.) torque. 8. Refill the differential with MOPAR Hypoid Gear Lubricant, or equivalent, to bottom of the fill plug hole. 9. Install the fill hole plug and lower the vehicle. Tighten fill plug to 34 Nm (25 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Front Axle > Page 1032 Fluid - Differential: Service and Repair Rear Axle 1. Raise and support the vehicle. 2. Remove the lubricant fill hole plug from the differential housing cover. 3. Remove the differential housing cover and drain the lubricant from the housing. 4. Clean the housing cavity with a flushing oil, light engine oil, or lint free cloth. Do not use water, steam, kerosene, or gasoline for cleaning. 5. Remove the original sealant from the housing and cover surfaces. Fig. 8 6. Apply a bead of MOPAR Silicone Rubber Sealant. or equivalent. to the housing cover. Install the housing cover within 5 minutes after applying the sealant. 7. Install the cover and any identification tag. Tighten the cover bolts to 41 Nm (30 ft. lbs.) torque. 8. For Trac-LOC differentials, a quantity of MOPAR Trac-LOC lubricant (friction modifier), or equivalent, must be added after repair service or a lubricant change. 9. Fill differential with MOPAR Hypoid Gear Lubricant, or equivalent, to bottom of the fill plug hole. CAUTION: Overfilling the differential can result in lubricant foaming and overheating. 10. Install the fill hole plug and lower the vehicle. 11. Trac-LOC differential equipped vehicles should be road tested by making 10 to 12 slow figure-eight turns. This maneuver will pump the lubricant through the clutch discs to eliminate a possible chatter noise complaint. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications NV231 Transfer Case Transfer Case ...................................................................................................................................... ......................................................... 1.2L (2.5 Pints) NV242 Transfer Case Transfer Case ...................................................................................................................................... ......................................................... 1.3L (2.8 Pints) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 1037 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid MOPAR Dexron II, or ATF Plus 3 type 9602 automatic transmission fluid Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Page 1038 Fluid - Transfer Case: Service Precautions DO NOT over fill transfer case beyond normal fluid level. Fluid foaming and damage may occur. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Without Filter Change .......................................................................................................................... ............................................................. 4.2L (4.5 Qt) Capacity shown is without filter. When replacing filter, additional oil may be needed Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1043 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................... SH or SH/CD or Above Above 0°F (-18°C).............................................. ........................................................................................................................................................ 10W-30 Below 32°F (0°C).................................................................................................................... ..................................................................................... 5W-30 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service Precautions > Customer Safety Information Engine Oil: Customer Safety Information 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. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service Precautions > Customer Safety Information > Page 1046 Engine Oil: Technician Safety Information 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service Precautions > Page 1047 Engine Oil: Description and Operation 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 Engine Oil Container Standard Notations In gasoline engines, use an engine oil that is API Service Grade Certified. 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. MOPAR(R) only provides engine oil that conforms to this certification. SAE VISCOSITY Temperature/Engine Oil Viscosity Recommendation An SAE viscosity grade is used to specify the viscosity of engine oil. SAE BOW-30 specifies a multiple viscosity engine oil. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. When choosing an engine oil, consider the range of temperatures the vehicle will be operated in before the next oil change. Select an engine oil that is best suited to your area's particular ambient temperature range and variation. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service Precautions > Page 1048 Engine Oil: Testing and Inspection CRANKCASE OIL LEVEL INSPECTION CAUTION: Do not overfill crankcase with engine oil, oil foaming and oil pressure loss can result. 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 PRESSURE 1. Disconnect connector and remove oil pressure sending unit. 2. Install Oil Pressure Line and Gauge Tool C-3292 or equivalent. Start engine and record pressure. Refer to Oil Pressure in Engine Specifications for the correct pressures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service Precautions > Page 1049 Engine Oil: Service and Repair Change engine oil at mileage and time intervals described in the Maintenance Schedule. This information can be found in your owner's manual. TO CHANGE ENGINE OIL 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 and gasket 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1054 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1055 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1056 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Power steering fluid Power steering capacities are dependant on engine/chassis options as well as steering gear/cooler options. Depending on type ans size of internal cooler, length and inside diameter of lines, or use of an auxiliary cooler, this capacity may vary. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 1059 Power Steering Fluid: Fluid Type Specifications All models Mopar Power Steering Fluid or equivalent Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Page 1060 Power Steering Fluid: Service Precautions DO NOT use automatic transmission fluid instead of Mopar Power Steering Fluid. System damage can result. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R134a Single Capacity ........................................................................................................................ ........................................ 0.79 kg (28 oz. or 1.75 lbs) R134a Dual Capacity ........................................................................................................................... ....................................... 0.85 kg (30 oz. or 1.87 lbs) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1065 Refrigerant: Fluid Type Specifications Hydrofluorocarbon (HFC), ................................................................................................................... ............................................... R-134a liquefied gas Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil Capacities Chart Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1070 Refrigerant Oil: Fluid Type Specifications Synthetic-based, Polyalkylene Glycol .................................................................................................. ......................................................................... SP-20 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1071 Refrigerant Oil: Service and Repair 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures W/ Four Wheel Antilock Brakes ABS system bleeding requires conventional bleeding methods plus use of the DRB scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. W/ Rear Wheel Antilock Brakes 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. Do not pump the brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles that are distributed throughout the hydraulic system. This will make additional bleeding operations necessary. Do not allow the master cylinder to run out of fluid during bleed operations. An empty cylinder will allow additional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed. Bleed only one brake component at a time in the following sequence: Master Cylinder - Combination Valve - Rear Antilock Valve - Left Rear Wheel - Right Rear Wheel - Right Front Wheel - Left Front Wheel MANUAL BLEEDING 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. Bleed Hose Setup 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 1076 PRESSURE BLEEDING 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 the adapter provided with the equipment or Adapter 6921. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 1077 Brake Bleeding: Service and Repair Base Brake System 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. Do not pump the brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles that are distributed throughout the hydraulic system. This will make additional bleeding operations necessary. Do not allow the master cylinder to run out of fluid during bleed operations. An empty cylinder will allow additional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed. Bleed only one brake component at a time in the following sequence: Master Cylinder - Combination Valve - Rear Antilock Valve - Right Rear Wheel - Left Rear Wheel - Right Front Wheel - Left Front Wheel MANUAL BLEEDING 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. Bleed Hose Setup 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. PRESSURE BLEEDING 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming Disconnect and isolate the battery negative cable. If the airbag module has not been deployed, wait two minutes for the system capacitor to discharge before further service. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 1082 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming 16-Way Data Link Connector - Typical 1. Make sure no one is in the vehicle. 2. Connect the negative battery terminal. 3. Connect the DRB scan tool to the 16-way data link wire harness connector. The connector is located on the driver side lower edge of the instrument panel, outboard of the steering column. 4. Turn the ignition switch to the ON position. Exit the vehicle with the DRB. Use the latest version of the proper DRB cartridge. 5. Erase the stored DTC data. If any problems remain, the stored DTC data will not erase. 6. With the ignition switch still in the ON position, make sure nobody is in the vehicle. 7. From outside of the vehicle (away from the airbag modules in case of an accidental deployment) turn the ignition switch to the OFF position for about 10 seconds, and then back to the ON position. Observe the airbag indicator lamp in the instrument cluster. It should light for six to 8 seconds, and then go out. This indicates that the airbag system is functioning normally. NOTE: If the airbag indicator lamp fails to light, or lights and stays on, there is an airbag system malfunction. Refer to the proper Diagnostic Procedures to diagnose the problem. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > DTC's - Caused By Open Fuses Fuse: Technical Service Bulletins DTC's - Caused By Open Fuses NUMBER: 18-09-99 GROUP: Vehicle Performance DATE: May 21, 1999 SUBJECT: Common Diagnostic Trouble Codes Caused By An Open Fuse. MODELS: 1999 (AB) Ram Van 1999 (AN) Dakota 1999 (BR/BE) Ram Truck 1999 (DN) Durango 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1999 (XJ) Cherokee DISCUSSION: Recent quality analysis has revealed an issue with repeated repairs for the same Diagnostic Trouble Code (DTC). The DTC may be due to an overlooked open circuit used to power the component in question. In most instances, either the circuit fuse has been erroneously removed or the fuse itself has an open (blown). The component in question, and its circuit, are often protected by two fuses. It is usually the lower amperage fuse that is either missing or open. The lower amperage fuse is positioned electrically in the circuit between the component in question and either a relay (Auto Shut Down, 02 heater) or the ignition switch. The lower amperage fuse will be located either in the underhood Power Distribution Center (PDC) or in the instrument panel Junction Block. The lower amperage fuse is often missing because it was removed erroneously for use in another low current circuit. If the lower amperage fuse is open (blown), then the circuit and component in question must be checked for an electrical short. Check to make sure that the open fuse was not exchanged with another fuse or was damaged by an installed accessory. NOTE: IF AN OXYGEN SENSOR IS REPLACED, VERIFY THAT THE CIRCUIT FUSE IS GOOD. AN OXYGEN SENSOR HEATER, WHEN DAMAGED OR OVERHEATED, MAY SHORT THE CIRCUIT AND CAUSE THE FUSE TO OPEN (BLOW). The higher amperage fuse should be checked, but is not normally the cause of the DTC. The higher amperage fuse is located in the underhood PDC. It is positioned electrically in the circuit between the battery and either the relay (Auto Shut Down, 02 heater) or the ignition switch. Refer to the applicable Diagnostic Procedures Manual and/or Service Manual (Group 8) for further technical assistance. The following is a list of the components frequently replaced erroneously due to an open fuse. Included are the possible DTC(s) which would be generated as a result. 1). Oxygen Sensor (02) P0132 ($3E) = 1/1 02 Sensor Shorted to Voltage P0135 ($67) = 1/1 02 Sensor Heater Failure P0138 ($7E) = 1/2 02 Sensor Shorted to Voltage P0141 ($69) = 1/2 02 Sensor Heater Failure P0152 ($42) = 2/1 02 Sensor Shorted To Voltage P0155 ($7C) = 2/1 02 Sensor Heater Failure P0158 ($7F) = 2/2 02 Sensor Shorted To Voltage P0161 ($7D) = 2/2 02 Sensor Heater Failure 2). Leak Detection Pump (LDP) P1495 ($B7) = Leak Detection Pump Solenoid Circuit Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > DTC's - Caused By Open Fuses > Page 1088 3). Evaporative Purge Solenoid (DCP) P0443 ($12) = Evaporative Purge Solenoid Circuit 4). Torque Converter Clutch Solenoid (TCC) P0743 ($OC) = Torque Converter Clutch Solenoid / Trans Relay Circuits POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1091 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1092 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1093 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1094 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1095 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1096 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1097 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1098 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1099 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1100 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1101 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1102 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1103 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1104 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1105 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1106 Fuse: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1107 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1108 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1109 Fuse: Connector Views Relay And Fuse Box Fuses Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1110 Fuse: Electrical Diagrams 8w-11-003 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1111 8w-11-004 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1112 8w-11-005 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Specifications Fuse Block: Specifications Tighten the one screw that secures the junction block to the left instrument panel end bracket to 2.2 Nm (20 in. lbs.). Tighten the one screw that secures the junction block to the left instrument panel end bracket to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Specifications > Page 1116 Fuse Block: Locations Junction (Fuse) Block Junction Block Relay And Fuse Block Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1119 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1120 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1121 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1122 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1123 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1124 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1125 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1126 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1127 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1128 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1129 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1130 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1131 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1132 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1133 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1134 Fuse Block: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1135 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1136 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1137 Fuse Block: Connector Views 8w-12-2 Junction Block (Front View) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1138 8w-12-3 Junction Block (Rear View) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1139 8w-12-4 Fuses Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1140 8w-11-002 Fuse Block Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1141 Fuse Block: Electrical Diagrams Fuse Block 8w-11-003 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1142 8w-11-004 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1143 8w-11-005 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Junction Block Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1144 8w-12-5 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1145 8w-12-6 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1146 8w-12-7 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1147 8w-12-8 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1148 8w-12-9 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1149 8w-12-10 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1150 8w-12-11 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1151 8w-12-12 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1152 8w-12-13 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1153 8w-12-14 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1154 8w-12-15 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1155 8w-12-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1156 Fuse Block: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO 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 AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1157 Fuse Block: Description and Operation DESCRIPTION Junction Block Junction Block An electrical Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. 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 junction block fuses. 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 label to ensure proper fuse identification. The JB combines the functions previously provided by a separate fuseblock module and relay center, 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. 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. 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). Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. The fuses, circuit breakers, and relays are available for service replacement. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or if the JB housing is faulty or damaged, the entire JB unit must be replaced. Relay And Fuse Block An additional relay and fuse block is used on this model. 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. 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 Junction Block (JB) or the Power Distribution Center (PDC). Relay And Fuse Block Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1158 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 is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. The relay and fuse block has cavities for up to four additional blade-type mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. The fuses, flasher and relays are available for service replacement. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Junction Block Replacement Fuse Block: Service and Repair Junction Block Replacement WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO 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 AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. Fuse Access Panel Remove/Install 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. Reaching through the instrument panel fuse access panel opening, remove the one screw that secures the junction block to the left instrument panel end bracket. 4. Remove the steering column opening cover from the instrument panel. Refer to Steering Column Opening Cover/Service and Repair of Instrument Panel Systems for the procedures. 5. Reach through the outboard side of the instrument panel steering column opening to access the junction block. Junction Block Remove/Install 6. Disconnect all of the wire harness connectors from the connector receptacles on the back of the junction block. 7. Still reaching through the instrument panel steering column opening, remove the relay and fuse block from the junction block. 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. 8. Still reaching through the outboard side of the instrument panel steering column opening, remove the one screw that secures the junction block to the left instrument panel end bracket. 9. Remove the junction block from the left instrument panel end bracket. INSTALLATION 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 old JB to the proper cavities of the new JB. 1. Position the junction block onto the left instrument panel end bracket. 2. 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.). 3. Install the relay and fuse block onto the junction block by engaging its mounting slots with the tabs on the junction block. 4. Reconnect all of the wire harness connectors to the connector receptacles on the back of the junction block. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Junction Block Replacement > Page 1161 5. Install the steering column opening cover onto the instrument panel. Refer to Steering Column Opening Cover/Service and Repair of Instrument Panel Systems for the procedures. 6. Reaching through the instrument panel fuse access panel opening, 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Junction Block Replacement > Page 1162 Fuse Block: Service and Repair Relay and Fuse Block Replacement 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 if 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 AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the dash panel. Refer to Instrument Panel Assembly in Instrument Panel Systems for the procedures. 3. Disconnect each of the instrument panel wire harness connectors. 4. Remove all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. 5. Disengage each of the retainers that secure the instrument panel wire harness to the instrument panel components. 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. 7. Remove the relay and fuse block and the instrument panel wire harness from the instrument panel as a unit. INSTALLATION 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 old relay and fuse block to the proper cavities of the new relay and fuse block. 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. 3. Engage each of the retainers that secure the instrument panel wire harness to the instrument panel components. 4. Install all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. 5. Reconnect each of the instrument panel wire harness connectors. 6. Install the instrument panel assembly onto the dash panel. 7. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations Relay Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Maintenance Required Lamp .............................................................................................................. .............................................................. PC194 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Application and ID Malfunction Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Check Engine Light ............................................................................................................................. .............................................................. PC194 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 1176 Oil Change Reminder Lamp: Service and Repair This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity and reinstall. Do not exceed speeds of 50 MPH. Refer to Owner's Manual for complete details. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation Wheels: Description and Operation 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 1185 Wheels: Testing and 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 1186 Wheels: Service and Repair The wheel studs and nuts are designed for specific applications. They must be replaced with equivalent parts. Do not use replacement parts of lesser quality or a substitute design. All aluminum and some steel wheels have wheel stud nuts which feature an enlarged nose. This enlarged nose is necessary to ensure proper retention of the aluminum wheels. NOTE: Do not use chrome plated lug nuts with chrome plated wheels. Before installing the wheel, be sure to remove any build up of corrosion on the wheel mounting surfaces. Ensure wheels are installed with good metal-to-metal contact. Improper installation could cause loosening of wheel nuts. This could affect the safety and handling of your vehicle. To install the wheel, first position it properly on the mounting surface. All wheel nuts should then be tightened just snug. Gradually tighten them in sequence to the proper torque specification. Never use oil or grease on studs or nuts. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Front Hub Seals - Grease Purge Explanation Wheel Bearing: Technical Service Bulletins Front Hub Seals - Grease Purge Explanation NUMBER: 02-06-99 Rev. A GROUP: Suspension DATE: Dec. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-06-99, DATED JUNE 11, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF 4X2 MODELS AND ADDITIONAL MODEL YEARS. SUBJECT: Front Wheel Bearing Grease Is Evident On The Bearing Seal Area. MODELS: 1997 - **2000** (AN) Dakota 1994 - **2000** (BR/BE) Ram Truck 1998 - **2000** (DN) Durango DISCUSSION: Front wheel bearings may be incorrectly diagnosed as faulty due to the evidence of wheel bearing grease on the bearing seal areas. This grease purge is a normal design condition. The factory fill of the bearings includes a slightly greater amount of grease than is required for the bearing lifetime lubricant. A portion of the grease purges through the self-venting seal in the initial few thousand miles to form an additional barrier in the area of the seal and the stamped slinger. This barrier aids in the prevention of contaminants passing through the seal and into the bearing. Do not remove or clean the purged grease as part of normal maintenance due to the fact that it provides additional protection and once removed, damage to the seal and bearing could result. NOTE: UNDER NORMAL CONDITIONS, THERE MAY BE A SPLATTERING OF GREASE RADIALLY OUTWARD ON THE STEERING KNUCKLE FROM THE GREASE BARRIER AREA THAT CAN BE AS THICK AS 4 MM (0.125 IN.). Front wheel bearings should be replaced only if: ^ The seal shows visible damage ^ The bearing endplay is greater than 0.13 mm (0.005 in.) ^ The bearing was operated without the proper clamping force from the spindle nut ^ The bearing has a rough, sticky feel when rotated POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 1191 Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 1192 Wheel Bearing: Service Precautions Use only a grease that is recommended for wheel bearing applications. Use of the improper grease can cause bearing damage. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Refer to Axle Shaft, Conventional Fixed/Floating, Axle Shaft Seal for procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1195 Wheel Bearing: Service and Repair Rear Refer to Axle Shaft, Conventional Fixed/Floating, Axle Shaft Seal for procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Nut, Axle 180 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence Wheel Fastener: Specifications Wheel Tightening Sequence Wheel Torque Sequence - Master Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 1204 Wheel Fastener: Specifications Lug Nut Torque Lug Nut ................................................................................................................................................ ................................ 115 - 157 Nm (85 - 115 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1205 Wheel Fastener: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper and rotor. Fig. 9 4. Remove stud from hub with Remover C-4150A. INSTALLATION 1. Install new stud into hub flange. 2. Install three washers onto stud, then install lug nut with the flat side of the nut against the washers. 3. Tighten lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange. 4. Remove lug nut and washers. 5. Install the brake rotor and caliper. 6. Install wheel and tire assembly, use new lug nut on stud or studs that were replaced. 7. Remove support and lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression should not be less than 689 kPa (100 psi) and not vary more than 172 kPa (25 psi) from cylinder to cylinder. If cylinder(s) have abnormally low compression pressures, repeat procedure. - If the same cylinder(s) repeat an abnormally low reading, it could indicate the existence of a problem in the cylinder. NOTE: The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should NOT be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1211 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST 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. (Refer to Powertrain Management for the correct procedure) 5. Disconnect the ignition coil. 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. Refer to Engine Specifications for the correct engine compression pressures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications BEARING DIAMETERS: No.1 ..................................................................................................................................................... .......... 50.800 - 50.825 mm (2.0000 - 2.0010 inch) No.2 ..................................................................... .......................................................................................... 50.394 - 50.419 mm (1.9840 - 1.9850 inch) No.3 ............................................................................................................................................ ................... 50.013 - 50.038 mm (1.9690 - 1.9700 inch) No.4 ............................................................ ................................................................................................... 49.606 - 49.632 mm (1.9530 1.9540 inch) No.5 ................................................................................................................................ ............................... 39.688 - 39.713 mm (1.5625 - 1.5635 inch) DIAMETRICAL CLEARANCE: Standard ............................................................................................................................................................ 0.0254 - 0.0762 mm 10.001 - 0.003 inch) Max. Allowable .................................................................. ........................................................................................................... 0.127 mm (0.005 inch) BEARING JOURNAL DIAMETER: No.1 ..................................................................................................................................................... .......... 50.749 - 50.775 mm (1.9980 - 1.9990 inch) No.2 ..................................................................... .......................................................................................... 50.343 - 50.368 mm (1.9820 - 1.9830 inch) No.3 ............................................................................................................................................ ................... 49.962 - 49.987 mm (1.9670 - 1.9680 inch) No.4 ............................................................ ................................................................................................... 49.555 - 49.581 mm (1.9510 1.9520 inch) No.5 ................................................................................................................................ ............................... 39.637 - 39.662 mm (1.5605 - 1.5615 inch) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Page 1216 Camshaft Bearing: Service and Repair Bearing caps are not interchangeable and should be marked at removal to ensure correct assembly. Upper and lower bearing halves are NOT interchangeable. Lower main bearing halves of No.2 and 4 are interchangeable. Main Bearing Identification Upper and lower No.3 bearing halves are flanged to carry the crankshaft thrust loads. They are NOT interchangeable with any other bearing halves in the engine. Bearing shells are available in standard and the following undersizes: 0.25 mm (0.001 inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm (0.010 inch) and 0.305 mm (0.012 inch). Never install an undersize bearing that will reduce clearance below specifications. REMOVAL NOTE: This procedure requires that the engine is removed from the vehicle. 1. With engine completely disassembled, drive out rear cam bearing core hole plug. Camshaft Bearings Removal/Installation With Tool C-3132-A 2. Install proper size adapters and horseshoe washers (part of Camshaft Bearing Remover/Installer Tool C-3132-A) at back of each bearing shell. Drive out bearing shells. INSTALLATION 1. Install new camshaft bearings with Camshaft Bearing Remover/Installer Tool C-3132-A by sliding the new camshaft bearing shell over proper adapter. 2. Position rear bearing in the tool. Install horseshoe lock and by reversing removal procedure, carefully drive bearing shell into place. 3. Install remaining bearings in the same manner. Bearings must be carefully aligned to bring oil holes into full register with oil passages from the main bearing. If the camshaft bearing shell oil holes are not in exact alignment, remove and install them correctly. Install a new core hole plug at the rear of camshaft. Be sure this plug does not leak. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt ....................................................................................................................... .................................................... 68 Nm (50 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Bearing Diameter (Inside) No.1 2.000 - 2.001 in No.2 1.984 - 1.985 in No. 3 1.953 - 1.954 in No.4 1.5265 - 1.5635 in Journal Diameter No.1 1.998 - 1.999 in No.2 1.982 - 1.983 in No. 3 1.951 - 1.952 in No.4 1.5605 - 1.5615 in Bearing to Journal Clearance Standard 0.001 - 0.003 in Max. Allowable 0.005 in Camshaft End Play 0.002 - 0.010 in Camshaft Pulley Bolts 210 in.lb Valve Timing Exhaust Valve Closes (ATDC) 33 deg Opens (BBDC) 56 deg Duration 269 deg Intake Valve Closes (ABDC) 62 deg Opens (BTDC 7 deg Duration 249 deg Valve Overlap 41 deg Camshaft Bolt 50 ft.lb Lift (at zero lash) - Intake 0.410 in Lift (at zero lash) - Exhaust 0.417 in Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement Camshaft: Service and Repair Camshaft Replacement Camshaft And Sprocket Assembly NOTE: The camshaft has an integral oil pump and distributor drive gear. REMOVAL 1. Remove the radiator. Refer to Cooling System for the correct procedures. 2. Remove the A/C Condenser (if equipped) 3. Remove the engine cover. 4. Remove intake manifold. Refer to Intake Manifolds for the correct procedure. 5. Remove cylinder head covers. 6. Remove timing case cover and timing chain. 7. Remove rocker arms. 8. Remove push rods and tappets. Identify each part so it can be installed in its original location. 9. Remove distributor and lift out the oil pump and distributor drive shaft. Timing Chain Oil Tab Installation 10. Remove camshaft thrust plate, note location of oil tab. 11. Install a long bolt into front of camshaft to facilitate removal of the camshaft. Remove camshaft, being careful not to damage cam bearings with the cam lobes. INSTALLATION 1. Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 51 mm (2 inches) of its final position in cylinder block. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 1225 Camshaft Holding Tool C-3509 (Installed Position) 2. Install Camshaft Gear Installer Tool C-3509 with tongue back of distributor drive gear. 3. Hold tool in position with a distributor lockplate bolt. This tool will restrict camshaft from being pushed in too far and prevent knocking out the welch plug in rear of cylinder block. Tool should remain installed until the camshaft and crankshaft sprockets and timing chain have been installed. 4. Install camshaft thrust plate and chain oil tab. Make sure tang enters lower right hole in thrust plate. Tighten bolts to 24 Nm (210 inch lbs.) torque. Top edge of tab should be flat against thrust plate in order to catch oil for chain lubrication. 5. Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores. 6. Place timing chain around both sprockets. 7. Turn crankshaft and camshaft to line up with keyway location in crankshaft sprocket and in camshaft sprocket. 8. Lift sprockets and chain (keep sprockets tight against the chain in position as described). Alignment Of Timing Marks 9. Slide both sprockets evenly over their respective shafts and use a straightedge to check alignment of timing marks. 10. Install the camshaft bolt/cup washer. Tighten bolt to 68 Nm (50 ft. lbs.) torque. 11. Measure camshaft end play. Refer to Specifications for proper clearance. If not within limits install a new thrust plate. 12. Each tappet reused must be installed in the same position from which it was removed. When camshaft is replaced, all of the tappets must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 1226 Camshaft: Service and Repair Shaft Prealignments NOTE: Before installing the distributor, the oil pump drive shaft must be aligned to number one cylinder. 1. Rotate crankshaft until No.1 cylinder is at top dead center on the firing stroke. 2. When in this position, the timing mark of vibration damper should be under "O" on the timing indicator. Position Of Oil Pump Shaft Slot 3. Install the shaft so that after the gear spirals into place, it will index with the oil pump shaft. The slot on top of oil pump shaft should be aligned towards the left front intake manifold attaching bolt hole. 4. Install distributor. After the distributor has been installed, its rotational position must be set using the SET SYNC mode of the DRB scan tool. Do not attempt to adjust ignition timing by rotating the distributor. It has no effect on ignition timing. Adjusting distributor position will effect fuel synchronization only. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications Lifter / Lash Adjuster: Specifications Body Diameter 0.9035 - 0.9040 in Clearance in Block 0.0011 - 0.0024 in Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Removal and Installation Lifter / Lash Adjuster: Service and Repair Removal and Installation REMOVAL 1. Remove the air cleaner. 2. Remove cylinder head cover. 3. Remove rocker assembly and push rods. Identify push rods to ensure installation in original location. 4. Remove intake manifold. 5. Remove yoke retainer and aligning yokes. 6. Slide Hydraulic Tappet Remover/Installer tool through opening in cylinder head and seat tool firmly in the head of tappet. 7. Pull tappet out of bore with a twisting motion. If all tappets are to be removed, identify tappets to ensure installation in original location. 8. If the tappet or bore in cylinder block is scored, scuffed, or shows signs of sticking, ream the bore to next oversize. Replace with oversize tappet. INSTALLATION 1. Lubricate tappets. 2. Install tappets and push rods in their original positions. Ensure that the oil feed hole in the side of the tappet body faces up (away from the crankshaft). 3. Install aligning yokes with ARROW toward camshaft. 4. Install yoke retainer. Tighten the bolts to 23 Nm (200 inch lbs.) torque. Install intake manifold. 5. Install push rods in original positions. 6. Install rocker arm. 7. Install cylinder head cover. 8. Install distributor, start engine and reset timing. CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become quiet. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Removal and Installation > Page 1232 Lifter / Lash Adjuster: Service and Repair Disassembly and Assembly CAUTION: The plunger and tappet bodies are not interchangeable. The plunger and valve must always be fitted to the original body. It is advisable to work on one tappet at a time to avoid mixing of parts. Mixed parts are not compatible. DO NOT disassemble a tappet on a dirty work bench. DISASSEMBLE Hydraulic Tappet Assembly 1. Pry out plunger retainer spring clip. 2. Clean varnish deposits from inside of tappet body above plunger cap. 3. Invert tappet body and remove plunger cap, plunger, check valve, check valve spring, check valve retainer and plunger spring. Check valve could be flat or ball. ASSEMBLE 1. Clean all tappet parts in a solvent that will remove all varnish and carbon. 2. Replace tappets that are unfit for further service with new assemblies. 3. If plunger shows signs of scoring or wear, install a new tappet assembly. If valve is pitted, or valve seat on end of plunger is prevented from seating, install a new tappet assembly. 4. Assemble tappets. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Specifications Push Rod: Specifications Push Rod Length 6.915 - 6.935 in Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Bolts 21 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1239 Rocker Arm Assembly: Service and Repair REMOVAL 1. Disconnect spark plug wires by pulling on the boot straight out in line with plug. 2. Remove cylinder head cover and gasket. Rocker Arms 3. Remove the rocker arm bolts and pivots. Place them on a bench in the same order as removed. 4. Remove the push rods and place them on a bench in the same order as removed. INSTALLATION 1. Rotate the crankshaft until the "V8" mark lines up with the TDC mark on the timing chain case cover. This mark is located 147° ATDC from the No. 1 firing position. 2. Install the push rods in the same order as removed. 3. Install rocker arm and pivot assemblies in the same order as removed. Tighten the rocker arm bolts to 28 Nm (21 ft. lbs.) torque. CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes). 4. Install cylinder head cover. 5. Connect spark plug wires. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Bearing Clearance .................................................................................................................................................... 0.013-0.056 mm (0.0005-0.0022 in) Side Clearance .................................................................................................................................... ........................... 0.152-0.356 mm (0.006-0.014 in) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1244 Connecting Rod Bearing: Description and Operation Engine connecting rod bearing clearances can be determined by use of Plastigage, or equivalent. The following is the recommended procedure for the use of Plastigage: 1. Remove oil film from surface to be checked. Plastigage is soluble in oil. 2. Place a piece of Plastigage across the entire width of the bearing cap shell. Position the Plastigage approximately 6.35 mm. (1/4 inch) off center and away from the oil holes. In addition, suspect areas can be checked by placing the Plastigage in the suspect area. 3. The crankshaft must be rotated until the connecting rod to be checked starts moving toward the top of the engine. Only then should the rod cap, with Plastigage in place, be assembled. Tighten the rod cap nut to 61 Nm (45 ft. lbs.) torque. DO NOT rotate the crankshaft or the Plastigage may be smeared, giving inaccurate results. 4. Remove the bearing cap and compare the width of the flattened Plastigage with the scale provided on the package. Plastigage generally comes in two scales (one scale is in inches and the other is a metric scale). Locate the band closest to the same width. This band shows the amount of clearance. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Refer to Engine Specifications. 5. Plastigage is available in a variety of clearance ranges. The 0.025 - 0.076 mm, (0.001 - 0.003 inch) range is usually the most appropriate for checking engine bearing clearances. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1245 Connecting Rod Bearing: Service and Repair Fit all rods on a bank until completed. DO NOT alternate from one bank to another, because connecting rods and pistons are not interchangeable from one bank to another. The bearing caps are not interchangeable and should be marked at removal to ensure correct assembly. Each bearing cap has a small V-groove across the parting face. When installing the lower bearing shell, make certain that the V-groove in the shell is in line with the V-groove in the cap. This provides lubrication of the cylinder wall in the opposite bank. The bearing shells must be installed so that the tangs are in the machined grooves in the rods and caps. Limits of taper or out-of-round on any crankshaft journals should be held to 0.025 mm. (0.001 inch). Bearings are available in 0.025 mm (0.001 inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm (0.010 inch) and 0.305 mm (0.012 inch) undersize. Install the bearings in pairs. DO NOT use a new bearing half with an old bearing half. DO NOT file the rods or bearing caps. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Cap Bolts/Nuts Connecting Rod: Specifications Connecting Rod Cap Bolts/Nuts Cap Bolts ............................................................................................................................................. ................................................. 61 Nm (45 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Cap Bolts/Nuts > Page 1250 Connecting Rod: Specifications Connecting Rod Specifications Bearing Clearance ................................................................................................................................................. 0.013 0.056 mm (0.0005 - 0.0022 inch) Max. Allowable ............................................................................... .................................................................................................... 0.08 mm (0.003 inch) Piston Pin Bore Diameter .................................................................................................................................. 24.966 - 24.978 mm (0.9829 - 0.9834 inch) Side Clearance (Two Rods) ...................................................................................................................................... 0.152 - 0.356 mm (0.006 - 0.014 inch) Total Weight (Less Bearing) ......................................................................................................................................................... 758 grams (25.74 ounces) Cap Bolts ............................................................................................................................................. ..................................................... 61 Nm (45 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1251 Connecting Rod: Service and Repair Refer to Piston, Engine, Service and Repair For Procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Rebuild Specifications Crankshaft Main Bearing: Specifications Rebuild Specifications Main Bearing Journals Diameter .............................................................................................................................................................. 71.361-71.387 mm (2.8095-2.8105 in.) Out-of-Round (Max) .............................................................. ........................................................................................................ 0.0254 mm (0.001 in.) Taper (Max) ................................................................................................................................................... ................................ 0.0254 mm (0.001 in.) Diametrical Clearance No. 1 .................................................................................................................................................... .................... 0.013-0.038 mm (0.0005-0.0015 in.) Service Limit (No. 1) ............................................ ....................................................................................................................... 0.0381 mm (0.0015 in.) No. 2,3,4,5 ........................................................................................................................................... .................... 0.013-0.051 mm (0.0005-0.0002 in.) Service Limit (Nos. 2,3,4,5) .......................................................................................................................................................... 0.064 mm (0.0025 in.) End Play .............................................................................................................................................. ........................ 0.051-0.178 mm (0.002-0.178 in.) Service Limit ........................................................ ............................................................................................................................ 0.254 mm (0.010 in.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Rebuild Specifications > Page 1256 Crankshaft Main Bearing: Specifications Torque Specifications Cap Bolts ............................................................................................................................................. .................................................. 115 Nm (85 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Removal and Installation Crankshaft Main Bearing: Service and Repair Removal and Installation REMOVAL 1. Remove the oil pan. 2. Remove the oil pump from the rear main bearing cap. 3. Identify bearing caps before removal. Remove bearing caps one at a time. Upper Main Bearing Removal And Installation With Tool C-3059 4. Remove upper half of bearing by inserting Crankshaft Main Bearing Remover/Installer Tool C-3059 into the oil hole of crankshaft. 5. Slowly rotate crankshaft clockwise, forcing out upper half of bearing shell. INSTALLATION Only one main bearing should be selectively fitted while all other main bearing caps are properly tightened. All bearing cap bolts removed during service procedures are to be cleaned and oiled before installation. When installing a new upper bearing shell, slightly chamfer the sharp edges from the plain side. 1. Start bearing in place, and insert Crankshaft Main Bearing Remover/Installer Tool C-3059 into oil hole of crankshaft. 2. Slowly rotate crankshaft counterclockwise sliding the bearing into position. Remove Tool C-3059. 3. Install the bearing cap. Clean and oil the bolts. Tighten the cap bolts to 115 Nm (85 ft. lbs.) torque. 4. Install the oil pump. 5. Install the oil pan. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Removal and Installation > Page 1259 Crankshaft Main Bearing: Service and Repair Fitting Bearings Bearing caps are not interchangeable and should be marked at removal to ensure correct assembly. Upper and lower bearing halves are NOT interchangeable. Lower main bearing halves of No.2 and 4 are interchangeable. Main Bearing Identification Upper and lower No.3 bearing halves are flanged to carry the crankshaft thrust loads. They are NOT interchangeable with any other bearing halves in the engine. Bearing shells are available in standard and the following undersizes: 0.25 mm (0.001 inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm (0.010 inch) and 0.305 mm (0.012 inch). Never install an undersize bearing that will reduce clearance below specifications. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Rod Journal Diameter 2.124 - 2.125 in Out of Round (Max.) 0.001 in Taper (Max.) 0.001 in Bearing Clearance 0.0005 - 0.0022 in Service Limit 0.003 in Main Journal Diameter 2.8095 - 2.8105 in Out of Round (Max.) 0.001 in Taper (Max.) 0.001 in Bearing Clearance (#1) 0.0005 - 0.0015 in Service Limit (#1) 0.0015 in Bearing Clearance (#2-5) 0.0005 - 0.0020 in Service Limit (#2-5) 0.0025 in Crankshaft End Play End Play 0.002 - 0.007 in Service Limit 0.010 in Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation Crankshaft: Service and Repair Removal and Installation Location Of Crankshaft Identification A crankshaft which has undersize journals will be stamped with 1/4 inch letters on the milled flat on the No.3 crankshaft counterweight. FOR EXAMPLE: R2 stamped on the No.3 crankshaft counterweight indicates that the No.2 rod journal is 0.025 mm. (0.001 inch) undersize. M4 indicates that the No.4 main journal is 0.025 mm. (0.001 inch) undersize. R3 M2 indicates that the No.3 rod journal and the No.2 main journal are 0.025 mm (0.001 inch) undersize. When a crankshaft is replaced, all main and connecting rod bearings should be replaced with new bearings. Therefore, selective fitting of the bearings is not required when a crankshaft and bearings are replaced. REMOVAL 1. Remove the oil pan. 2. Remove the oil pump from the rear main bearing cap. 3. Remove the vibration damper. 4. Remove the timing chain cover. 5. Identify bearing caps before removal. Remove bearing caps and bearings one at a time. 6. Lift the crankshaft out of the block. 7. Remove and discard the crankshaft rear oil seals. 8. Remove and discard the front crankshaft oil seal. INSPECTION OF JOURNALS The crankshaft connecting rod and main journals should be checked for excessive wear, taper and scoring. The maximum taper or out-of-round on any crankshaft journal is 0.025 mm (0.001 inch). Journal grinding should not exceed 0.305 mm (0.012 inch) under the standard journal diameter. DO NOT grind thrust faces of No.3 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all oil passages. CAUTION: After any journal grind, it is important that the final paper or cloth polish be in the same direction as the engine rotates. CLEANING Clean Loctite 518 residue and sealant from the cylinder block and rear cap mating surface. Do this before applying the Loctite drop and the installation of rear cap. INSTALLATION 1. Lightly oil the new upper seal lips with engine oil. 2. Install the new upper rear bearing oil seal with the white paint facing towards the rear of the engine. 3. Position the crankshaft into the cylinder block. 4. Lightly oil the new lower seal lips with engine oil. 5. Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1265 Sealant Application To Bearing Cap 6. Apply 5 mm (0.20 inch) drop of Loctite 518, or equivalent, on each side of the rear main bearing cap. DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. 7. To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement. 8. Clean and oil all cap bolts. Install all main bearing caps. Install all cap bolts and alternately tighten to 115 Nm (85 ft. lbs.) torque. 9. Install oil pump. Apply Sealant To Bearing Cap To Block Joint Apply Mopar(R) Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing. Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove. 10. Install new front crankshaft oil seal. 11. Immediately install the oil pan. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1266 Crankshaft: Service and Repair Cleaning and Inspection INSPECTION OF JOURNALS The crankshaft connecting rod and main journals should be checked for excessive wear, taper and scoring. The maximum taper or out-of-round on any crankshaft journal is 0.025 mm (0.001 inch). Journal grinding should not exceed 0.305 mm (0.012 inch) under the standard journal diameter. DO NOT grind thrust faces of No.3 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all oil passages. CAUTION: After any journal grind, it is important that the final paper or cloth polish be in the same direction as the engine rotates. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1267 Crankshaft: Service and Repair Service Procedures OVERVIEW Location Of Crankshaft Identification A crankshaft which has undersize journals will be stamped with 1/4 inch letters on the milled flat on the No.3 crankshaft counterweight. FOR EXAMPLE: R2 stamped on the No.3 crankshaft counterweight indicates that the No.2 rod journal is 0.025 mm. (0.001 inch) undersize. M4 indicates that the No.4 main journal is 0.025 mm (0.001 inch) undersize. R3 M2 indicates that the No.3 rod journal and the No.2 main journal are 0.025 mm (0.001 inch) undersize. When a crankshaft is replaced, all main and connecting rod bearings should be replaced with new bearings. Therefore, selective fitting of the bearings is not required when a crankshaft and bearings are replaced. INSPECTION OF JOURNALS The crankshaft connecting rod and main journals should be checked for excessive wear, taper and scoring. The maximum taper or out-of-round on any crankshaft journal is 0.025 mm (0.001 inch). Journal grinding should not exceed 0.305 mm (0.012 inch) under the standard journal diameter. DO NOT grind thrust faces of No.3 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all oil passages. CAUTION: After any journal grind, it is important that the final paper or cloth polish be in the same direction as the engine rotates. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications Engine Block Heater: Specifications Block Heater Bolt 17 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 1271 Engine Block Heater: Description and Operation An optional engine block heater is available for 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. Connect power cord to a grounded 110 - 120 volt AC electrical outlet with a grounded, three wire extension cord. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 1272 Engine Block Heater: Service and Repair REMOVAL 1. Disconnect battery negative cable. 2. Drain coolant from radiator and cylinder block. Refer to Cooling System- Draining and Filling. Block Heater Removal/installation 3. Remove power cord from block heater. 4. Loosen screw at center of block heater. Remove heater assembly. INSTALLATION 1. Thoroughly clean cylinder block core hole and block heater seat. 2. Insert block heater assembly with element loop pointing down. 3. With block heater fully seated, tighten center screw to 2 Nm (17 inch lbs.) torque. 4. Fill cooling system with recommended coolant. 5. Start and warm the engine. Check for leaks. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Testing and Inspection Expansion/Freeze Plug: Testing and Inspection OIL LINE PLUG Oil Line Plug The oil line plug is located in the vertical passage at the rear of the block between the Oil-To-Filter and Oil-From-Filter passages. Improper installation or plug missing could cause erratic, low or no oil pressure. 1. Remove oil pressure sending unit from back of block. 2. Insert a 3.175 mm (1/8 inch) finish wire or equivalent into passage. 3. Plug should be 190.0 to 195.2 mm (7-1/2 to 7-11/16 inches) from machined surface of block. If plug is too high, use a suitable flat dowel drift to position properly. 4. If plug is too low, remove oil pan and rear main bearing cap. Use suitable flat dowel to properly position. Coat outside diameter of plug with Mopar(R) (stud and bearing mount adhesive), or equivalent. Plug should be 54.0 to 57.7 mm (2 1/8 to 2 - 5/16 inches) from bottom of the block. 5. Assemble engine and check oil pressure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Testing and Inspection > Page 1276 Expansion/Freeze Plug: Service and Repair ENGINE CORE PLUGS Location Of Cup Plugs In Oil Galleries Engine core plugs have been pressed into the oil galleries behind the camshaft thrust plate. This will reduce internal leakage and help maintain higher oil pressure at idle. REMOVAL Core Hole Plug Removal 1. Using a blunt tool such as a drift or a screwdriver and a hammer, strike the bottom edge of the cup plug. 2. With the cup plug rotated, grasp firmly with pliers or other suitable tool and remove plug. CLEANING Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer. Make certain the new plug is cleaned of all oil or grease. INSTALLATION 1. Coat edges of plug and core hole with Mopar(R) Gasket Maker, or equivalent. CAUTION: DO NOT drive cup plug into the casting as restricted coolant flow can result and cause serious engine problems. 2. Using proper plug drive, drive cup plug into hole. The sharp edge of the plug should be at least 0.50 mm (0.020 inch) inside the lead-in chamfer. 3. It is not necessary to wait for curing of the sealant. The cooling system can be filled and the vehicle placed in service immediately. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Damper <--> [Harmonic Balancer - Crankshaft Pulley] > Component Information > Specifications > Crankshaft Pulley Crankshaft Damper: Specifications Chrankshaft Pulley Chrankshaft Pulley Torque Specifications 24 Nm (210 in.lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Damper <--> [Harmonic Balancer - Crankshaft Pulley] > Component Information > Specifications > Crankshaft Pulley > Page 1281 Crankshaft Damper: Specifications Vibration Damper Bolt 135 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Damper <--> [Harmonic Balancer - Crankshaft Pulley] > Component Information > Specifications > Page 1282 Crankshaft Damper: Service and Repair REMOVAL 1. Disconnect the battery negative cable. 2. Remove the cooling system fan. 3. Remove the cooling fan shroud. 4. Remove the accessory drive belt (refer to Drive Belts, Mounts, Brackets and Accessories System). 5. Remove the vibration damper pulley. 6. Remove vibration damper bolt and washer from end of crankshaft. Vibration Damper Assembly 7. Install bar and screw from Puller Tool Set C-3688. Install 2 bolts with washers through the puller tool and into the vibration damper. 8. Pull vibration damper off of the crankshaft. INSTALLATION 1. Position the vibration damper onto the crankshaft. Installing Vibration Damper 2. Place installing tool, part of Puller Tool Set C-3688 in position and press the vibration damper onto the crankshaft. 3. Install the crankshaft bolt and washer. Tighten the bolt to 183 Nm (135 ft. lbs.) torque. 4. Install the crankshaft pulley. Tighten the pulley bolts to 23 Nm (200 inch lbs.) torque. 5. Install the accessory drive belt (refer to Drive Belts, Mounts, Brackets and Accessories System). 6. Position the fan shroud and install the bolts. Tighten the retainer bolts to 11 Nm (95 inch lbs.) torque. 7. Install the cooling fan. 8. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Clearance at Top of Skirt 0.0005 - 0.0015 in Land Clearance (Diam.) 0.020 - 0.026 in Piston Length 3.19 in Ring Groove Depth (#1and2) 0.187 - 0.193 in Ring Groove Depth (#3) 0.157 - 0.164 in Weight 20.53 - 20.67 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1286 Piston: Description and Operation The pistons are elliptically turned so that the diameter at the pin boss is less than its diameter across the thrust face. This allows for expansion under normal operating conditions. Under operating temperatures, expansion forces the pin bosses away from each other, causing the piston to assume a more nearly round shape. All pistons are machined to the same weight, regardless of size, to maintain piston balance. The piston pin rotates in the piston only and is retained by the press interference fit of the piston pin in the connecting rod. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation Piston: Service and Repair Removal and Installation REMOVAL 1. Remove the engine from the vehicle. 2. Remove the cylinder head. 3. Remove the oil pan. 4. 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. 5. Be sure the connecting rod and connecting rod cap are identified with the cylinder number. Remove connecting rod cap. Install connecting rod bolt guide set on connecting rod bolts. 6. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies, rotate crankshaft to center the connecting rod in the cylinder bore and at BDC. Be careful not to nick crankshaft journals. 7. After removal, install bearing cap on the mating rod. INSTALLATION 1. Be sure that compression ring gaps are staggered so that neither is in-line with oil ring rail gap. Proper Ring Installation 2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located properly. 3. Immerse the piston head and rings in clean engine oil. Slide Piston Ring Compressor Tool C-385 over the piston and tighten with the special wrench (part of Tool C-385). Be sure position of rings does not change during this operation. 4. Install connecting rod bolt protectors on rod bolts, the long protector should be installed on the numbered side of the connecting rod. 5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Be sure connecting rod and cylinder bore number are the same. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal. 6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on crankshaft journal. 7. The notch or groove on top of piston must be pointing toward front of engine. The larger chamfer of the connecting rod bore must be installed toward crankshaft journal fillet. 8. Install rod caps. Be sure connecting rod, connecting rod cap and cylinder bore number are the same. Install nuts on cleaned and oiled rod bolts and tighten nuts to 61 Nm (45 ft. lbs.) torque. 9. Install the oil pan. 10. Install the cylinder head. 11. Install the engine into the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1289 Piston: Service and Repair Cleaning and Inspection Check the crankshaft connecting rod journal for excessive wear, taper and scoring. Check the cylinder block bore for out-of-round, taper, scoring and scuffing. Piston Measurement Check the pistons for taper and elliptical shape before they are fitted into the cylinder bore. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1290 Piston: Service and Repair Fitting Pistons Piston and cylinder wall must be clean and dry. Specified clearance between the piston and the cylinder wall is 0.013 - 0.038 mm (0.0005 - 0.0015 inch) at 21°C (70°F). Piston diameter should be measured at the top of skirt, 90° to piston pin axis. Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line. Pistons and cylinder bores should be measured at normal room temperature, 21°C (70°F). Piston Measurements Check the Pistons for taper and elliptical shape before they are fitted into the cylinder bore. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Clearance in Piston 0.00023 - 0.00074 in Diameter 0.9845 - 0.9848 in End Play None Length 2.67 - 2.69 in Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Ring Gap Compression Ring (Top) 0.012 - 0.022 in Compression Ring (2nd) 0.022 - 0.031 in Oil Control (Steel Rails) 0.015 - 0.055 in Ring Side Clearance Compression Rings 0.0016 - 0.0033 in Oil Control (Steel Rails) 0.002 - 0.008 in Ring Width Compression Rings 0.060 - 0.061 in Oil Control (Steel Rails) - Max. 0.018 - 0.019 in Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1297 Piston Ring: Service and Repair 1. Measurement of end gaps: a. Measure piston ring gap 2 inches from bottom of cylinder bore. An inverted piston can be used to push the rings down to ensure positioning rings squarely in the cylinder bore before measuring. b. Insert feeler gauge in the gap. The top compression ring gap should be between 0.254 - 0.508 mm (0.010 - 0.020 inch). The second compression ring gap should be between 0.508 - 0.762 mm (0.020 - 0.030 inch). The oil ring gap should be 0.254 - 1.270 min (0.010 - 0.050 inch). c. Rings with insufficient end gap may be properly filed to the correct dimension. Rings with excess gaps should not be used. 2. Install rings and confirm ring side clearance: a. Install oil rings being careful not to nick or scratch the piston. Install the oil control rings according to instructions in the package. It is not necessary to use a tool to install the upper and lower rails. Insert oil rail spacer first, then side rails. Second Compression Ring Identification (Typical) Compression Ring Chamfer Location (Typical) b. Install the second compression rings using Installation Tool C-4184. The compression rings must be installed with the identification mark face up (toward top of piston) and chamfer facing down. An identification mark on the ring is a drill point, a stamped letter "0", an oval depression or the word TOP. Top Compression Ring Identification (Typical) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1298 Proper Ring Installation c. Using a ring installer, install the top compression ring with the chamfer facing up. An identification mark on the ring is a drill point, a stamped letter "0", an oval depression or the word TOP facing up. d. Measure side clearance between piston ring and ring land. Clearance should be 0.074 - 0.097 mm (0.0029 - 0.0038 inch) for the compression rings. The steel rail oil ring should be free in groove, but should not exceed 0.246 mm (0.0097 inch) side clearance. e. Pistons with insufficient or excessive side clearance should be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all times. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Use following procedure if fuel rail is or is not equipped with fuel pressure test port. 1. Remove fuel fill cap. 2. The fuel filler tube contains a spring-loaded flap (door) located below fuel fill cap. The flap is used as a secondary way of sealing fuel tank if fuel fill cap has not been properly tightened. It is part of EVAP monitor system when vehicle is equipped with a Leak Detection Pump (LDP). The vehicle may be equipped with flap installed into fuel filler tube even though vehicle is not equipped with LDP and EVAP monitor system. Place a nonmetallic object into fuel fill tube and press on flap to relieve any tank pressure. 3. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. 6. 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. 7. Unplug connector from any injector. 8. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 9. Connect other end of jumper wire to positive side of battery. 10. 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. 11. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 12. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 13. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 14. Return fuel pump relay to PDC. 15. 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. Refer to Emission Control System. See On-Board Diagnostics. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Bolts 21 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1309 Rocker Arm Assembly: Service and Repair REMOVAL 1. Disconnect spark plug wires by pulling on the boot straight out in line with plug. 2. Remove cylinder head cover and gasket. Rocker Arms 3. Remove the rocker arm bolts and pivots. Place them on a bench in the same order as removed. 4. Remove the push rods and place them on a bench in the same order as removed. INSTALLATION 1. Rotate the crankshaft until the "V8" mark lines up with the TDC mark on the timing chain case cover. This mark is located 147° ATDC from the No. 1 firing position. 2. Install the push rods in the same order as removed. 3. Install rocker arm and pivot assemblies in the same order as removed. Tighten the rocker arm bolts to 28 Nm (21 ft. lbs.) torque. CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes). 4. Install cylinder head cover. 5. Connect spark plug wires. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair Valve Cover: Service and Repair Cylinder Head Cover Gasket A steel backed silicon gasket is used with the cylinder head cover. This gasket can be used again. REMOVAL 1. Disconnect the negative cable from the battery. 2. Disconnect closed ventilation system and evaporation control system from cylinder head cover. 3. Remove cylinder head cover and gasket. The gasket may be used again. INSTALLATION 1. Clean cylinder head cover gasket surface. 2. Clean head rail, if necessary. 3. Inspect cover for distortion and straighten, if necessary. 4. Check the gasket for use in head cover installation. If damaged, use a new gasket. 5. Position the cylinder head cover onto the gasket. Tighten the bolts to 11 Nm (95 inch lbs.) torque. 6. Install closed crankcase ventilation system and evaporation control system. 7. Connect the negative cable to the battery. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Service and Repair Valve Guide: Service and Repair Measure valve stem guide clearance as follows: Positioning Valve With Tool C-3973 1. Install Valve Guide Sleeve Tool C-3973 over valve stem and install valve. The special sleeve places the valve at the correct height for checking with a dial indicator. Measuring Valve Guide Wear 2. Attach Dial Indicator Tool C-3339 to cylinder head and set it at right angle of valve stem being measured. 3. Move valve to and from the indicator. The total dial indicator reading should not exceed 0.432 mm (0.017 inch). Ream the guides for valves with oversize stems if dial indicator reading is excessive or if the stems are scuffed or scored. Reamer Sizes Service valves with oversize stems are available. Slowly turn reamer by hand and clean guide thoroughly before installing new valve. Ream the valve guides from standard to 0.381 mm (0.015 inch). Use a 2 step procedure so the valve guides are reamed true in relation to the valve seat: ^ Step 1-Ream to 0.0763 mm (0.003 inch). ^ Step 2-Ream to 0.381 mm. (0.015 inch). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Angle 44.25 - 44.75 deg Runout (Max.) 0.003 in Width (Finish) - Intake 0.040 - 0.060 in Width (Finish) - Exhaust 0.060 - 0.080 in Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications > Page 1319 Valve Seat: Service and Repair Refer to Valves, Intake/Exhaust, Service and Repair for procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Free Length 1.967 in Spring Tension (valve closed) 85 lbf at 1.64 in Spring Tension (valve open) 200 lbf at 1.212 in Number of Coils 6.8 Installed Height 1.64 in Wire Diameter 0.177 in Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head Off Valve Spring: Service and Repair Cylinder Head Off Refer to Valves, Intake/Exhaust, Service and Repair for procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head Off > Page 1325 Valve Spring: Service and Repair Cylinder Head On 1. Remove the air cleaner. 2. Remove cylinder head covers and spark plugs. 3. Remove coil wire from distributor and secure to good ground to prevent engine from starting. 4. Using suitable socket and flex handle at crankshaft retaining bolt, turn engine so the No.1 piston is at TDC on the compression stroke. 5. Remove rocker arms. 6. With air hose attached to an adapter installed in No.1 spark plug hole, apply 620 - 689 kPa (90 - 100 psi) air pressure. 7. Using Valve Spring Compressor Tool MD-998772A with adaptor 6716A, compress valve spring and remove retainer valve locks and valve spring. 8. Install seals on the exhaust valve stem and position down against valve guides. 9. The intake valve stem seals should be pushed firmly and squarely over the valve guide using the valve stem as a guide. DO NOT force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks. 10. Follow the same procedure on the remaining 7 cylinders using the firing sequence 1-8-4-3-6-5-7-2. Make sure piston in cylinder is at TDC on the valve spring that is being removed. 11. Remove adapter from the No.1 spark plug hole. 12. Install rocker arms. 13. Install covers and coil wire to distributor. 14. Install air cleaner. 15. Road test vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head Off > Page 1326 Valve Spring: Service and Repair Inspection Testing Valve Spring For Compressed Length Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested. As an example the compression length of the spring to be tested is 1-5/16 inch. Turn table of Universal Valve Spring Tester Tool until surface is in line with the 1-5/16 inch mark on the threaded stud. Be sure the zero mark is to the front. Place spring over stud on the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by 2. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Refer to specifications to obtain specified height and allowable tensions. Discard the springs that do not meet specifications. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Face Angle 43.25 - 43.75 deg Head Diameter - Intake 1.88 in Head Diameter - Exhaust 1.617 in Length (Overall) - Intake 4.696 - 4.994 in Length (Overall) - Exhaust 4.978 - 5.012 in Stem Diameter - Intake 0.372 - 0.373 in Stem Diameter - Exhaust 0.371 - 0.372 in Stem to Guide Clearance - Intake 0.001 - 0.003 in Stem to Guide Clearance - Exhaust 0.002 - 0.004 in Service Limit 0.017 in Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1330 Valve: Description and Operation The valves are arranged in-line and are inclined 18°. The rocker pivot support and the valve guides are cast integral with the heads. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1331 Valve: Testing and Inspection VALVE CLEANING Clean valves thoroughly Discard burned, warped and cracked valves. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. VALVE INSPECTION Measure valve stems for wear. If wear exceeds 0.051 mm (0.002 inch), replace the valve. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation Valve: Service and Repair Removal and Installation REMOVAL 1. Remove the cylinder head. 2. Compress valve springs using Valve Spring Compressor Tool MD-998772A. 3. Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. 4. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to ensure installation in original location. INSTALLATION 1. Coat valve stems with lubrication oil and insert them in cylinder head. 2. If valves or seats are reground, check valve stem height. If valve is too long, replace cylinder head. 3. Install new seals on all valve guides. Install valve springs and valve retainers. 4. Compress valve springs with Valve Spring Compressor Tool MD-998772A, install locks and release tool. If valves and/or seats are ground, measure the installed height of springs. Make sure the measurement is taken from bottom of spring seat in cylinder head to the bottom surface of spring retainer. If spacers are installed, measure from the top of spacer. If height is greater than 42.86 mm (1 - 11/16 inches), install a 1.587 mm (1/16 inch) spacer in head counterbore. This should bring spring height back to normal 41.27 to 42.86 mm (1 - 5/8 to 1 - 11/16 inch). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1334 Valve: Service and Repair Valve Service VALVE CLEANING Clean valves thoroughly Discard burned, warped and cracked valves. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. VALVE INSPECTION Measure valve stems for wear. If wear exceeds 0.051 mm (0.002 inch), replace the valve. VALVE GUIDES Measure valve stem guide clearance as follows: Positioning Valve With Tool C-3973 1. Install Valve Guide Sleeve Tool C-3973 over valve stem and install valve. The special sleeve places the valve at the correct height for checking with a dial indicator. Measuring Valve Guide Wear 2. Attach Dial Indicator Tool C-3339 to cylinder head and set it at right angle of valve stem being measured. 3. Move valve to and from the indicator. The total dial indicator reading should not exceed 0.432 mm (0.017 inch). Ream the guides for valves with oversize stems if dial indicator reading is excessive or if the stems are scuffed or scored. Reamer Sizes Service valves with oversize stems are available. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1335 Slowly turn reamer by hand and clean guide thoroughly before installing new valve. Ream the valve guides from standard to 0.381 mm (0.015 inch). Use a 2 step procedure so the valve guides are reamed true in relation to the valve seat: ^ Step 1-Ream to 0.0763 mm (0.003 inch). ^ Step 2-Ream to 0.381 mm. (0.015 inch). REFACING VALVES AND VALVE SEATS Valve Face And Seat Angles The intake and exhaust valves have a 43-1/4° to 43-3/4° face angle and a 44-1/4° to 44-3/4° seat angle. VALVES Intake And Exhaust Valves Inspect the remaining margin after the valves are refaced. Valves with less than 1.190 mm (0.047 inch) margin should be discarded. VALVE SEATS Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1336 Refacing Valve Seats CAUTION: DO NOT unshroud valves during valve seat refacing. 1. When refacing 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. 2. Measure the concentricity of valve seat using a dial indicator. Total runout should not exceed 0,051 mm (0.002 inch) total indicator reading. 3. Inspect the valve seat with Prussian blue to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian blue then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is transferred to the top edge of valve face, lower valve seat with a 15° stone. If the blue is transferred to bottom edge of valve face raise valve seat with a 60° stone. 4. When seat is properly positioned the width of intake seats should be 1.016-1.524 min (0.040 0.060 inch). The width of the exhaust seats should be 1.524 - 2.032 mm. (0.060 - 0.080 inch). VALVE SPRING INSPECTION Testing Valve Spring For Compressed Length Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested. As an example the compression length of the spring to be tested is 1-5/16 inch. Turn table of Universal Valve Spring Tester Tool until surface is in line with the 1-5/16 inch mark on the threaded stud. Be sure the zero mark is to the front. Place spring over stud on the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by 2. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Refer to specifications to obtain specified height and allowable tensions. Discard the springs that do not meet specifications. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Belt Wear Patterns When diagnosing serpentine accessory drive belts small cracks that run across the ribbed surface of the belt from rib to rib, 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. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer to the Accessory Drive Belt Diagnosis charts 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 1341 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 1342 ACCESSORY DRIVE BELT DIAGNOSIS CHART Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 1343 Drive Belt: Service and Repair REMOVAL Automatic Belt Tensioner-Belt Removal/Installation Drive belts these engines are equipped with a spring loaded automatic belt tensioner. This belt tensioner will be used on all belt configurations, such as with or without power steering or air conditioning. For more information, refer to Drive Belts, Mounts, Brackets and Accessories. 1. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 2. Rotate tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. 3. Remove belt from idler pulley first. 4. Remove belt from vehicle. INSTALLATION CAUTION: When installing serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. For correct 3.9L/ 5.2L/ 5.9L engine belt routing. The correct belt with correct length must be used. 1. Position drive belt over all pulleys except idler pulley. This pulley is located between generator and A/C compressor. 2. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 3. Rotate socket/wrench clockwise. Place belt over idler pulley. Let tensioner rotate back into place. Remove wrench. Be sure belt is properly seated on all pulleys. 4. Check belt indexing marks. Refer to the proceeding Automatic Belt Tensioner-3.9L/5.2L/5.9L Engine for more belt information. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 1344 Automatic Belt Tensioner/Pulley Assembly-3.9L/5.2L/5.9L Engine The tensioner is equipped with an indexing arrow on back of tensioner and an indexing mark on tensioner housing. If a new belt is being installed, arrow must be within approximately 3 mm (1/8 in.) of indexing mark (Point B-. Belt is considered new if it has been used 15 minutes or less. If this 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 Routing-3.9L/5.2L/5.9L Engine ^ Belt incorrectly routed. A used belt should be replaced if tensioner indexing arrow has moved beyond point A. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Automatic Belt Tensioner-3.9L/5.2L/5.9L Engine Correct accessory drive belt tension is required to be sure of optimum performance of 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. Drive belts on both 3.9L and 5.2L/5.9L engines are equipped with a spring loaded automatic belt tensioner. This belt tensioner will be used with all belt configurations. Such as with or without power steering or air conditioning. Due to use of this belt tensioner, do not attempt to use a belt tension gauge on 3.9L/5.2L/5.9L engines. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Description and Operation > Page 1348 Drive Belt Tensioner: Service and Repair REMOVAL 1. Attach a socket/wrench to mounting bolt of automatic tensioner pulley bolt. 2. Rotate tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. 3. Remove belt from idler pulley first. 4. Remove belt from other pulleys. 5. Disconnect wiring and secondary cable from ignition coil. 6. Remove ignition coil from coil mounting bracket (two bolts). Do not remove coil mounting bracket from cylinder head. 7. Remove tensioner assembly from mounting bracket (one nut). WARNING: BECAUSE OF HIGH SPRING PRESSURE, DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY (EXCEPT FOR PULLEY). 8. Remove pulley bolt. Remove pulley from tensioner. INSTALLATION 1. Install pulley and pulley bolt to tensioner. Tighten bolt to 61 Nm (45 ft. lbs.). 2. Install tensioner assembly to mounting bracket. An indexing tab is located on back of tensioner. Align this tab to slot in mounting bracket. Tighten nut to 67 Nm (50 ft. lbs.). 3. Connect all wiring to ignition coil. 4. Install coil to coil bracket. If nuts and bolts are used to secure coil to coil bracket, tighten to 11 Nm (100 inch lbs.) torque. If coil mounting bracket has been tapped for coil mounting bolts, tighten bolts to 5 Nm (50 inch lbs.) torque. CAUTION: To prevent damage to coil case, coil mounting bolts must be torqued. 5. Position drive belt over all pulleys except idler pulley (located between generator and A/C compressor). CAUTION: When installing serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. For correct 3.9LJ 5.2LJ5.9L engine belt routing. The correct belt with correct length must be used 6. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 7. Rotate socket/wrench clockwise. Place belt over idler pulley. Let tensioner rotate back into place. Remove wrench. Be sure belt is properly seated on all pulleys. 8. Check belt indexing marks. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications Engine Mount: Specifications Engine Support Bracket to Block 30 ft.lb Front Insulator Through bolt/nur 70 ft.lb Front Insulator to Supprot Bracket Stud Nut 30 ft.lb Front Insulator to Support Bracket Through bolt/nut 75 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications > Page 1352 Engine Mount: Service and Repair ENGINE MOUNTS-FRONT REMOVAL Right Engine Mount Insulator And Support Bracket Left Engine Mount Insulator And Support Bracket On 4WD vehicles the engine front support brackets attach directly to engine block and the axle housing. The brackets provide a solid interconnection for these units. Engine must be supported during any service procedures involving the front support assemblies. 1. Disconnect the negative cable from the battery. 2. Raise vehicle on hoist. 3. Install engine lifting (support) fixture. 4. Remove front axle assembly. 5. Left mount insulator only. Remove starter wires and starter motor assembly. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications > Page 1353 Engine Mount Insulator At Frame 6. Remove insulator to frame through bolt. 7. Raise engine slightly. 8. Remove upper insulator to support bracket stud nut and insulator to support through bolt. 9. Remove engine mount insulator. 10. If engine support bracket is to be removed/replaced, remove support bracket to transmission bell housing bolt(s) and three (3) support bracket to engine block bolts. Remove support bracket. INSTALLATION-4WD 1. If engine support brackets were removed, install them and their fasteners. Tighten support bracket to block bolts to 41 Nm (30 ft. lbs.). Tighten support bracket to transmission bellhousing bolt(s) to 88 Nm (65 ft. lbs.). 2. Install Engine mount insulator and tighten insulator to support bracket nut to 41 Nm (30 ft. lbs.). Tighten insulator to support bracket through bolt nut to 102 Nm (75 ft. lbs.). 3. Lower engine and install insulator to frame through bolt and nut. Tighten nut to 95 Nm (70 ft. lbs.). 4. Install starter motor and mounting bolts. Tighten bolts to 68 Nm (50 ft. lbs.). 5. Connect starter wires. 6. Remove engine lifting (support) fixture. 7. Install front axle assembly. 8. Lower the vehicle. 9. Connect the negative cable to the battery. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications OIL PRESSURE @ Curb Idle (Min.*) .............................................................................................................................. ................................................... 41.4 kPa (6 psi) @ 3000 rpm .......................................................... ................................................................................................................... 207 - 552 kPa (30 - 80 psi) Bypass Valve Setting .................................................................................................................... ............................................... 62 - 103 kPa (9 - 15 psi) Switch Actuating pressure ......................................................................................................................................................... 34.5 - 48.3 kPa (5 - 7 psi) CAUTION: If oil pressure is zero at curb idle, DO NOT RUN ENGINE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Description and Operation Engine Oil Dip Stick - Dip Stick Tube: Description and Operation Engine Oil Dipstick Location-3.9L/5.2L/5.9L Engines The engine oil level indicator is located at the right front of the engine, left of the generator on 3.9L and 5.2L/5.9L engines. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Without Filter Change .......................................................................................................................... ............................................................. 4.2L (4.5 Qt) Capacity shown is without filter. When replacing filter, additional oil may be needed Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1365 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................... SH or SH/CD or Above Above 0°F (-18°C).............................................. ........................................................................................................................................................ 10W-30 Below 32°F (0°C).................................................................................................................... ..................................................................................... 5W-30 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service Precautions > Customer Safety Information Engine Oil: Customer Safety Information 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. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service Precautions > Customer Safety Information > Page 1368 Engine Oil: Technician Safety Information 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service Precautions > Page 1369 Engine Oil: Description and Operation 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 Engine Oil Container Standard Notations In gasoline engines, use an engine oil that is API Service Grade Certified. 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. MOPAR(R) only provides engine oil that conforms to this certification. SAE VISCOSITY Temperature/Engine Oil Viscosity Recommendation An SAE viscosity grade is used to specify the viscosity of engine oil. SAE BOW-30 specifies a multiple viscosity engine oil. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. When choosing an engine oil, consider the range of temperatures the vehicle will be operated in before the next oil change. Select an engine oil that is best suited to your area's particular ambient temperature range and variation. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service Precautions > Page 1370 Engine Oil: Testing and Inspection CRANKCASE OIL LEVEL INSPECTION CAUTION: Do not overfill crankcase with engine oil, oil foaming and oil pressure loss can result. 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 PRESSURE 1. Disconnect connector and remove oil pressure sending unit. 2. Install Oil Pressure Line and Gauge Tool C-3292 or equivalent. Start engine and record pressure. Refer to Oil Pressure in Engine Specifications for the correct pressures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service Precautions > Page 1371 Engine Oil: Service and Repair Change engine oil at mileage and time intervals described in the Maintenance Schedule. This information can be found in your owner's manual. TO CHANGE ENGINE OIL 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 and gasket 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair Oil Filter: Service and Repair FILTER SPECIFICATION All engines are equipped with a high quality full flow, disposable type oil filter. Chrysler Corporation recommends a Mopar(R) or equivalent oil filter be used. OIL FILTER REMOVAL 1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench loosen filter. Oil Filter Removal-Typical 3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss. 4. when filter separates from adapter nipple, tip gasket end upward to minimize oil spill. Remove filter from vehicle. Oil Filter Sealing Surface-Typical 5. With a wiping cloth, clean the gasket sealing surface of oil and grime. OIL FILTER INSTALLATION 1. Lightly lubricate oil filter gasket with engine oil or chassis grease. 2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal and Installation Oil Pan: Service and Repair Removal and Installation REMOVAL 1. Disconnect the negative cable from the battery. 2. Remove engine oil dipstick. 3. Raise vehicle. 4. Drain engine oil. 5. Remove front axle assembly. 6. Remove both engine mount support brackets. 7. Remove transmission inspection cover. 8. Remove oil pan and one-piece gasket. INSTALLATION Fabrication Of Alignment Dowels 1. Fabricate 4 alignment dowels from 1 1/2 x 5/16 inch bolts. Cut the head off the bolts and cut a slot into the top of the dowel. This will allow easier installation and removal with a screwdriver. Position Of Dowels In Cylinder Block 2. Install the dowels in the cylinder block. 3. Apply small amount of Mopar(R) Silicone Rubber Adhesive Sealant, or equivalent in the corner of the cap and the cylinder block. 4. Slide the one-piece gasket over the dowels and onto the block. 5. Position the oil pan over the dowels and onto the gasket. 6. Install the oil pan bolts. Tighten the bolts to 24 Nm (215 inch lbs.) torque. 7. Remove the dowels. Install the remaining oil pan bolts. Tighten these bolts to 24 Nm (215 inch lbs.) torque. 8. Install the drain plug. Tighten drain plug to 34 Nm (25 ft. lbs.) torque. 9. Install transmission inspection cover. 10. Install engine mount support brackets and insulators. 11. Install front axle assembly. 12. Lower vehicle 13. Connect the distributor cap. 14. Install dipstick. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal and Installation > Page 1379 15. Connect the negative cable to the battery. 16. Fill crankcase with oil to proper level. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal and Installation > Page 1380 Oil Pan: Service and Repair Cleaning and Inspection CLEANING Clean the block and pan gasket surfaces. Trim or remove excess sealant film in the rear main cap oil pan gasket groove. DO NOT remove the sealant inside the rear main cap slots. If present, trim excess sealant from inside the engine. Clean oil pan in solvent and wipe dry with a clean cloth. Clean oil screen and pipe thoroughly in clean solvent. Inspect condition of screen. INSPECTION Inspect oil drain plug and plug hole for stripped or damaged threads. Repair as necessary. Inspect oil pan mounting flange for bends or distortion. Straighten flange, if necessary. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Component Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Component Locations > Page 1385 Oil Pressure Sending Unit/Switch, Camshaft Position Sensor Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 1386 Oil Pressure Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams Engine Oil Pressure Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Page 1390 Oil Pressure Sensor: Description and Operation OIL PRESSURE SENSOR-PCM INPUT Sends a signal from the oil pressure sending unit to the Powertrain Control Module (PCM) relating to engine oil pressure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Engine Oil Pressure Lamp ................................................................................................................... .............................................................. PC194 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 (Min.*) .............................................................................................................................. ................................................... 41.4 kPa (6 psi) @ 3000 rpm .......................................................... ................................................................................................................... 207 - 552 kPa (30 - 80 psi) Bypass Valve Setting .................................................................................................................... ............................................... 62 - 103 kPa (9 - 15 psi) Switch Actuating pressure ......................................................................................................................................................... 34.5 - 48.3 kPa (5 - 7 psi) CAUTION: If oil pressure is zero at curb idle, DO NOT RUN ENGINE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption Intake Manifold: Customer Interest Engine - Spark Knock/Oil Consumption NUMBER: 09-05-00 GROUP: Engine DATE: Feb.25, 2000 MODELS: 1994 - 1999 (AB) Ram Van 1994 - 1999 (AN) Dakota 1994 - 1999 (BRIBE) Ram Truck 1998 - 1999 (DN) Durango 1994 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-06-99, DATED SEP.10, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Spark Knock And Engine Oil Consumption Due To Intake Manifold Pan Gasket Oil Leak OVER VIEW: This bulletin involves the replacement of the engine intake manifold plenum pan gasket. NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH A 3.9L, 5.2L. OR 5.9L GASOLINE ENGINE. SYMPTOM/CONDITION: An engine intake manifold plenum pan gasket oil leak may occur on some V-6 and V-8 style engines. The oil leak is internal to the engine so no external oil leakage will be present. Two symptoms of this oil leak condition may be present. The vehicle operator may experience an engine spark knock during acceleration and/or an increase in the amount of engine oil consumed by the engine. DIAGNOSIS: Make sure Technical Service Bulletin (TSB) 18-48-98 has been performed. NOTE: IT IS IMPORTANT THAT THE COIL AND SPARK PLUG WIRES ARE ROUTED EXACTLY AS SPECIFIED IN TSB 18-48-98 TO ACHIEVE THE MOST BENEFIT. Inspect the Positive Crankcase Ventilation (PCV) valve. Shake the PCV valve to verify that the pintle inside of the PCV valve is free. Replace the PVC if the pintle is not free. If the intake manifold plenum pan gasket is leaking, an additional vacuum source will be created inside of the engine at the location of the pan gasket leakage. Engine combustion blow-by gases, oil vapor, and air from the crankcase filter/breather may be drawn past the leaking pan gasket and into the intake manifold. In most cases when this condition occurs, an engine at idle will create the highest vacuum and lowest amount of engine blow-by. 1. Allow the engine to reach normal operating temperature. 2. Stop the engine. 3. Disconnect the breather hose from the air cleaner. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1406 4. Attach a vacuum/pressure gauge to the end of the breather hose (Figure 1). 5. Disconnect the PCV valve hose from the intake manifold. 6. Seal off the intake manifold PCV valve hose port opening. 7. Seal off the open end of the PCV valve hose (Figure 2). NOTE: DURING THIS DIAGNOSIS, IT WOULD BE NORMAL FOR THE ENGINE TO DEVELOP PRESSURE WITHIN THE ENGINE CRANKCASE. THIS IS DUE TO THE NORMAL PROCESS OF EXHAUST BLOW-BY GASES LEAKING PAST THE ENGINE PISTON RINGS AND ACCUMULATING IN THE ENGINE CRANKCASE. DO NOT ALLOW MORE THAN 3 PSI (20.7 kpa) OF PRESSURE TO BUILD WITHIN THE ENGINE WHEN PERFORMING THE FOLLOWING DIAGNOSTIC PROCEDURE. 8. Start the warmed engine and observe the vacuum gauge. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1407 9. Allow the engine to idle for approximately 30 seconds. Do not allow more than 3 psi (20.7 kPa) of pressure to develop in the engine crankcase. 10. If the attached vacuum / pressure gauge does not indicate that a vacuum is present in the engine crankcase, then the intake manifold plenum pan gasket is good and no further internal engine vacuum leak diagnosis is required. 11. If an internal vacuum leak is present then perform the Repair Procedure. PARTS REQUIRED: For the 5.2L / 5.9L: 1 04897383AC Package, Intake Manifold Flange Gasket and Bolts 1 05017208AA Gasket, Intake Manifold Plenum Pan 15 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR) 04318001 Conditioner, Combustion Chamber For the 3.9L: 1 04897382AC Package, Intake Manifold Flange Gasket and Bolts 1 05017207AA Gasket, Intake Manifold Plenum Pan 14 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR)04318001 Conditioner, Combustion Chamber REPAIR PROCEDURE: 1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation instructions. NOTE: CLEAN ALL OIL RESIDUE FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND THE INTAKE MANIFOLD PLENUM CHAMBER. NOTE: THE PROPER BOLT TORQUE AND TIGHTENING SEQUENCE IS CRITICAL AND MUST BE FOLLOWED WHEN TIGHTENING BOTH THE PLENUM PAN BOLTS AND THE INTAKE MANIFOLD FLANGE BOLTS. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1408 3.9L Bolt Tightening Sequence and Torque Procedure: 3.9 Plenum Pan Bolt Torque Procedure 3.9 Intake Manifold Flange Bolt Torque Procedure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1409 5.2L / 5.9L Plenum Bolt Tightening Sequence and Torque Procedure: 5.2L / 5.9L Plenum Pan Bolt Torque Procedure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1410 5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure 2. With the engine reassembled, inspect the coil and spark plug wires for proper routing. Refer to TSB 09-48-98 for additional assistance. 3. Start the engine and allow it to warm to normal engine operating temperature. 4. Decarbon the combustion chamber using Mopar Combustion Chamber Conditioner (p/n 04318001) per the instructions. NOTE: ALLOW THE COMBUSTION CHAMBER CLEANER TO SOAK INSIDE OF THE ENGINE FOR 2 TO 2.5 HOURS. NOTE: A SECOND APPLICATION OF THE COMBUSTION CHAMBER CONDITIONER MAY BE REQUIRED IF THERE WAS A LARGE QUANTITY OF OIL LEAKAGE PAST THE INTAKE PLENUM PAN GASKET. 5. Verify proper engine oil level. POLICY: Reimbursable within the provisions of the warranty. Time Allowance FAILURE CODE: P8- New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption Intake Manifold: All Technical Service Bulletins Engine - Spark Knock/Oil Consumption NUMBER: 09-05-00 GROUP: Engine DATE: Feb.25, 2000 MODELS: 1994 - 1999 (AB) Ram Van 1994 - 1999 (AN) Dakota 1994 - 1999 (BRIBE) Ram Truck 1998 - 1999 (DN) Durango 1994 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-06-99, DATED SEP.10, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Spark Knock And Engine Oil Consumption Due To Intake Manifold Pan Gasket Oil Leak OVER VIEW: This bulletin involves the replacement of the engine intake manifold plenum pan gasket. NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH A 3.9L, 5.2L. OR 5.9L GASOLINE ENGINE. SYMPTOM/CONDITION: An engine intake manifold plenum pan gasket oil leak may occur on some V-6 and V-8 style engines. The oil leak is internal to the engine so no external oil leakage will be present. Two symptoms of this oil leak condition may be present. The vehicle operator may experience an engine spark knock during acceleration and/or an increase in the amount of engine oil consumed by the engine. DIAGNOSIS: Make sure Technical Service Bulletin (TSB) 18-48-98 has been performed. NOTE: IT IS IMPORTANT THAT THE COIL AND SPARK PLUG WIRES ARE ROUTED EXACTLY AS SPECIFIED IN TSB 18-48-98 TO ACHIEVE THE MOST BENEFIT. Inspect the Positive Crankcase Ventilation (PCV) valve. Shake the PCV valve to verify that the pintle inside of the PCV valve is free. Replace the PVC if the pintle is not free. If the intake manifold plenum pan gasket is leaking, an additional vacuum source will be created inside of the engine at the location of the pan gasket leakage. Engine combustion blow-by gases, oil vapor, and air from the crankcase filter/breather may be drawn past the leaking pan gasket and into the intake manifold. In most cases when this condition occurs, an engine at idle will create the highest vacuum and lowest amount of engine blow-by. 1. Allow the engine to reach normal operating temperature. 2. Stop the engine. 3. Disconnect the breather hose from the air cleaner. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1416 4. Attach a vacuum/pressure gauge to the end of the breather hose (Figure 1). 5. Disconnect the PCV valve hose from the intake manifold. 6. Seal off the intake manifold PCV valve hose port opening. 7. Seal off the open end of the PCV valve hose (Figure 2). NOTE: DURING THIS DIAGNOSIS, IT WOULD BE NORMAL FOR THE ENGINE TO DEVELOP PRESSURE WITHIN THE ENGINE CRANKCASE. THIS IS DUE TO THE NORMAL PROCESS OF EXHAUST BLOW-BY GASES LEAKING PAST THE ENGINE PISTON RINGS AND ACCUMULATING IN THE ENGINE CRANKCASE. DO NOT ALLOW MORE THAN 3 PSI (20.7 kpa) OF PRESSURE TO BUILD WITHIN THE ENGINE WHEN PERFORMING THE FOLLOWING DIAGNOSTIC PROCEDURE. 8. Start the warmed engine and observe the vacuum gauge. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1417 9. Allow the engine to idle for approximately 30 seconds. Do not allow more than 3 psi (20.7 kPa) of pressure to develop in the engine crankcase. 10. If the attached vacuum / pressure gauge does not indicate that a vacuum is present in the engine crankcase, then the intake manifold plenum pan gasket is good and no further internal engine vacuum leak diagnosis is required. 11. If an internal vacuum leak is present then perform the Repair Procedure. PARTS REQUIRED: For the 5.2L / 5.9L: 1 04897383AC Package, Intake Manifold Flange Gasket and Bolts 1 05017208AA Gasket, Intake Manifold Plenum Pan 15 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR) 04318001 Conditioner, Combustion Chamber For the 3.9L: 1 04897382AC Package, Intake Manifold Flange Gasket and Bolts 1 05017207AA Gasket, Intake Manifold Plenum Pan 14 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR)04318001 Conditioner, Combustion Chamber REPAIR PROCEDURE: 1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation instructions. NOTE: CLEAN ALL OIL RESIDUE FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND THE INTAKE MANIFOLD PLENUM CHAMBER. NOTE: THE PROPER BOLT TORQUE AND TIGHTENING SEQUENCE IS CRITICAL AND MUST BE FOLLOWED WHEN TIGHTENING BOTH THE PLENUM PAN BOLTS AND THE INTAKE MANIFOLD FLANGE BOLTS. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1418 3.9L Bolt Tightening Sequence and Torque Procedure: 3.9 Plenum Pan Bolt Torque Procedure 3.9 Intake Manifold Flange Bolt Torque Procedure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1419 5.2L / 5.9L Plenum Bolt Tightening Sequence and Torque Procedure: 5.2L / 5.9L Plenum Pan Bolt Torque Procedure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1420 5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure 2. With the engine reassembled, inspect the coil and spark plug wires for proper routing. Refer to TSB 09-48-98 for additional assistance. 3. Start the engine and allow it to warm to normal engine operating temperature. 4. Decarbon the combustion chamber using Mopar Combustion Chamber Conditioner (p/n 04318001) per the instructions. NOTE: ALLOW THE COMBUSTION CHAMBER CLEANER TO SOAK INSIDE OF THE ENGINE FOR 2 TO 2.5 HOURS. NOTE: A SECOND APPLICATION OF THE COMBUSTION CHAMBER CONDITIONER MAY BE REQUIRED IF THERE WAS A LARGE QUANTITY OF OIL LEAKAGE PAST THE INTAKE PLENUM PAN GASKET. 5. Verify proper engine oil level. POLICY: Reimbursable within the provisions of the warranty. Time Allowance FAILURE CODE: P8- New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1421 Intake Manifold: Specifications PLENUM PAN BOLTS Tighten the bolts, in sequence, as follows: ^ Step 1-Tighten bolts to 2.7 Nm (24 inch lbs.) torque. ^ Step 2-Tighten bolts to 5.4 Nm (48 inch lbs.) torque. ^ Step 3-Tighten bolts to 9.5 Nm (84 inch lbs.) torque. ^ Step 4-Check that all bolts are tighten to 9.5 Nm (84 inch lbs.) torque. MANIFOLD BOLTS Install the intake manifold bolts and tighten as follows: ^ Step 1-Tighten bolts 1 through 4, in sequence, to 8 Nm (72 inch lbs.) torque. Tighten in alternating steps 1.4 Nm (12 inch lbs.) torque at a time. ^ Step 2-Tighten bolts 5 through 12, in sequence, to 8 Nm (72 inch lbs.) torque. ^ Step 3-Check that all bolts are tighten to 8 Nm (72 inch lbs.) torque. ^ Step 4-Tighten all bolts, in sequence, to 16 Nm (12 ft. lbs.) torque. ^ Step 5-Check that all bolts are tighten to 16 Nm (12 ft. lbs.) torque. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1422 Intake Manifold: Description and Operation The aluminum intake manifold is a single plane design with equal length runners. The manifold is sealed by flange side gaskets with front and rear cross-over gaskets. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection Intake Manifold: Service and Repair Cleaning and Inspection CLEANING Clean manifold in solvent and blow dry with compressed air. Clean cylinder block front and rear gasket surfaces using a suitable solvent. The plenum pan rail must be clean and dry (free of all foreign material). INSPECTION Inspect manifold for cracks. Inspect mating surfaces of manifold for flatness with a straightedge. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1425 Intake Manifold: Service and Repair Intake Manifold Replacement REMOVAL 1. Disconnect the battery negative cable. 2. Drain the cooling system (refer to Cooling System for the proper procedures). 3. Remove the accessory drive belt. 4. Remove the generator. 5. Remove the air cleaner. 6. Remove the A/C compressor bracket. 7. Disconnect the accelerator linkage and if so equipped, the speed control and transmission kickdown cables. 8. Disconnect the MAP, IAC, and TPS sensor connectors. 9. Disconnect the fuel injector connectors. 10. Disconnect the coolant temperature sending unit connector(s). 11. Remove the distributor cap and wires. 12. Disconnect the heater hoses and bypass hose. 13. Disconnect the PCV, HVAC, and Speed Control vacuum supply hoses. 14. Perform the Fuel System Pressure Release procedure (refer to Powertrain Management). 15. Disconnect the fuel supply line. 16. Remove intake manifold bolts. 17. Lift the intake manifold and throttle body out of the engine compartment as an assembly. 18. Remove and discard the flange side gaskets and the front and rear cross-over gaskets. Throttle Body Assembly-MPI Typical 19. Remove the throttle body bolts and lift the throttle body off the intake manifold. Discard the gasket. 20. Remove the plenum pan as follows: a. Turn the intake manifold upside down. Support the manifold. b. Remove the bolts and lift the pan off the manifold. Discard the gasket. INSTALLATION 1. Install the plenum pan, if removed, as follows: a. Turn the intake manifold upside down. Support the manifold. b. Place a new plenum pan gasket onto the seal rail of the intake manifold. Position the pan over the gasket. Align all the gasket and pan holes with the intake manifold. Hand start all bolts. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1426 Plenum Pan Bolt Tightening Sequence d. Tighten the bolts, in sequence, as follows: ^ Step 1-Tighten bolts to 2.7 Nm (24 inch lbs.) torque. ^ Step 2-Tighten bolts to 5.4 Nm (48 inch lbs.) torque. ^ Step 3-Tighten bolts to 9.5 Nm (84 inch lbs.) torque. ^ Step 4-Check that all bolts are tighten to 9.5 Nm (84 inch lbs.) torque. 2. Using a new gasket, install the throttle body onto the intake manifold. Tighten the bolts to 23 Nm (200 inch lbs.) torque. Cross-Over Gaskets And Locator Dowels 3. Place the 4 plastic locator dowels into the holes in the block. 4. Apply Mopar(R) Silicone Rubber Adhesive Sealant, or equivalent, to the four corner joints. An excessive amount of sealant is not required to ensure a leak proof seal. However, an excessive amount of sealant may reduce the effectiveness of the flange gasket. The sealant should be slightly higher than the crossover gaskets, approx. 5 mm (0.2 inch). 5. Install the front and rear cross-over gaskets onto the dowels. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1427 Intake Manifold Flange Gasket Alignment 6. Install the flange gaskets. Ensure that the vertical port alignment tab is resting on the deck face of the block. Also the horizontal alignment tabs must be in position with the mating cylinder head gasket tabs. The words A1ANIFOLD SIDE should be visible on the center of each flange gasket. 7. Carefully lower intake manifold into position on the cylinder block and cylinder heads. Use the alignment dowels in the cross-over gaskets to position the intake manifold. After intake manifold is in place, inspect to make sure seals are in place. Intake Manifold Bolt Torque Sequence - (V-8) 8. Install the intake manifold bolts and tighten as follows: ^ Step 1-Tighten bolts 1 through 4, in sequence, to 8 Nm (72 inch lbs.) torque. Tighten in alternating steps 1.4 Nm (12 inch lbs.) torque at a time. ^ Step 2-Tighten bolts 5 through 12, in sequence, to 8 Nm (72 inch lbs.) torque. ^ Step 3-Check that all bolts are tighten to 8 Nm (72 inch lbs.) torque. ^ Step 4-Tighten all bolts, in sequence, to 16 Nm (12 ft. lbs.) torque. ^ Step 5-Check that all bolts are tighten to 16 Nm (12 ft. lbs.) torque. 9. Install the fuel supply line. Push until an audible "click" is heard. Verify connection by moderately pulling out on connector. 10. Install distributor cap and wires. 11. Connect the coolant temperature sending unit connector. 12. Connect the fuel injector connectors. 13. Connect the accelerator linkage and if so equipped, the speed control and transmission kickdown cables. 14. Connect the MAP, TPS, and IAC connectors. 15. Connect the brake booster, HVAC, speed control, and PCV vacuum supply hoses to the intake manifold. 16. Connect the heater hoses and bypass hose. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1428 17. Install the generator and drive belt. Tighten generator mounting bolt to 41 Nm (30 ft. lbs.) torque. Tighten the adjusting strap bolt to 23 Nm (200 inch lbs.) torque. Refer to Drive Belts, Mounts, Brackets and Accessories for the correct procedures and belt routing schematics. 18. Install the air cleaner. 19. Fill cooling system (refer to Cooling System for the proper procedure). 20. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Engine Oil Pressure Lamp ................................................................................................................... .............................................................. PC194 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair CRANKSHAFT REAR OIL SEALS The service seal is a 2 piece, Viton seal. The upper seal half can be installed with crankshaft removed from engine or with crankshaft installed. When a new upper seal is installed, install a new lower seal. The lower seal half can only be installed with the rear main bearing cap removed. UPPER SEAL REPLACEMENT-CRANKSHAFT REMOVED 1. Remove the crankshaft. Discard the old upper seal. 2. Clean the cylinder block rear cap mating surface. Make sure the seal groove is free of debris. 3. Lightly oil the new upper seal lips with engine oil. 4. Install the new upper rear bearing oil seal with the white paint facing towards the rear of the engine. 5. Position the crankshaft into the cylinder block. 6. Lightly oil the new lower seal lips with engine oil. 7. Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine. Sealant Application To Bearing Cap 8. Apply 5 min (0.20 inch) drop of Loctite 518, or equivalent, on each side of the rear main bearing cap. DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. 9. To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement. 10. Clean and oil all cap bolts. Install all main bearing caps. Install all cap bolts and alternately tighten to 115 Nm (85 ft. lbs.) torque. 11. Install oil pump. Apply Sealant To Bearing Cap To Block Joint 12. Apply Mopar(R) Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing. Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove. 13. Install new front crankshaft oil seal. 14. Immediately install the oil pan. UPPER SEAL REPLACEMENT-CRANKSHAFT INSTALLED 1. Remove the oil pan. 2. Remove the oil pump from the rear main bearing cap. 3. Remove the rear main bearing cap. Remove and discard the old lower oil seal. 4. Carefully remove and discard the old upper oil seal. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 1437 5. Clean the cylinder block mating surfaces before oil seal installation. 6. Lightly oil the new upper seal lips with engine oil. To allow ease of installation of the seal, loosen at least the 2 main bearing caps forward of the rear bearing cap. 7. Rotate the new upper seal into the cylinder block being careful not to shave or cut the outer surface of the seal. To assure proper installation, use the installation tool provided with the kit. Install the new seal with the white paint facing towards the rear of the engine. 8. Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine. 9. Apply 5 mm (0.20 inch) drop of Loctite 518, or equivalent, on each side of the rear main bearing cap. DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. Be sure the white paint faces toward the rear of the engine. 10. To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement. 11. Install the rear main bearing cap with cleaned and oiled cap bolts. Alternately tighten ALL cap bolts to 115 Nm (85 ft. lbs.) torque. 12. Install oil pump. 13. Apply Mopar(R) Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing. Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove. 14. Immediately install the oil pan. LOWER SEAL REPLACEMENT 1. Remove the oil pan. 2. Remove the oil pump from the rear main bearing cap. 3. Remove the rear main bearing cap and discard the old lower seal. 4. Clean the rear main cap mating surfaces including the oil pan seal grooves. 5. Carefully install a new upper seal (refer to Upper Seal Replacement - Crankshaft Installed procedure above). 6. Lightly oil the new lower seal lips with engine oil. 7. Install a new lower seal in bearing cap with white paint facing the rear of engine. 8. Apply 5 mm (0.20 inch) drop of Loctite 518, or equivalent, on each side of the rear main bearing cap. DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. 9. To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement. 10. Install the rear main bearing cap with cleaned and oiled cap bolts. Alternately tighten the cap bolts to 115 Nm (85 ft. lbs.) torque. 11. Install oil pump. 12. Apply Mopar(R) Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing. Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove. 13. Immediately install the oil pan. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Testing and Inspection Cylinder Head Gasket: Testing and Inspection FAILURE DIAGNOSIS A leaking engine cylinder head gasket usually results in loss of power, loss of coolant, and engine misfiring. An engine cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket. An engine cylinder head gasket leaking between adjacent cylinders is indicated by a loss of power and/or engine misfire. - An engine cylinder head gasket leaking between a cylinder and an adjacent water jacket is indicated by coolant foaming or overheating and loss of coolant. Cylinder To Cylinder Leakage Test To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the procedures outlined in Cylinder Compression Pressure Test. An engine cylinder head gasket leaking between adjacent cylinders will result in approximately a 50-70% reduction in compression pressure. Cylinder To Water Jacket Leakage Test 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, oft the fan. Do not wear loose clothing. Remove the radiator cap. Start the engine and allow it to warm up until the engine thermostat opens. If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant. If bubbles are not visible, install a radiator pressure tester and pressurize the coolant system. If a cylinder is leaking combustion pressure into the water jacket, the tester pointer will pulsate with every combustion stroke of the cylinder. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair The oil seal can be replaced without removing the timing chain cover provided the cover is not misaligned. 1. Disconnect the negative cable from the battery. 2. Remove vibration damper. 3. If front seal is suspected of leaking, check front oil seal alignment to crankshaft. The seal installation/alignment tool 6635, should fit with minimum interference. If tool does not fit, the cover must be removed and installed properly. 4. Place a suitable tool behind the lips of the oil seal to pry the oil seal outward. Be careful not to damage the crankshaft seal bore of cover. Placing Oil Seal On Installation Tool 6635 5. Place the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635. Seat the oil seal in the groove of the tool. Position Tool And Seal Onto Crankshaft 6. Position the seal and tool onto the crankshaft. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1444 Installing Oil Seal 7. Using the vibration damper bolt, tighten the bolt to draw the seal into position on the crankshaft. 8. Remove the vibration damper bolt and seal installation tool. 9. Inspect the seal flange on the vibration damper. 10. Install the vibration damper. 11. Connect the negative cable to the battery. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption Intake Manifold Gasket: Customer Interest Engine - Spark Knock/Oil Consumption NUMBER: 09-05-00 GROUP: Engine DATE: Feb.25, 2000 MODELS: 1994 - 1999 (AB) Ram Van 1994 - 1999 (AN) Dakota 1994 - 1999 (BRIBE) Ram Truck 1998 - 1999 (DN) Durango 1994 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-06-99, DATED SEP.10, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Spark Knock And Engine Oil Consumption Due To Intake Manifold Pan Gasket Oil Leak OVER VIEW: This bulletin involves the replacement of the engine intake manifold plenum pan gasket. NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH A 3.9L, 5.2L. OR 5.9L GASOLINE ENGINE. SYMPTOM/CONDITION: An engine intake manifold plenum pan gasket oil leak may occur on some V-6 and V-8 style engines. The oil leak is internal to the engine so no external oil leakage will be present. Two symptoms of this oil leak condition may be present. The vehicle operator may experience an engine spark knock during acceleration and/or an increase in the amount of engine oil consumed by the engine. DIAGNOSIS: Make sure Technical Service Bulletin (TSB) 18-48-98 has been performed. NOTE: IT IS IMPORTANT THAT THE COIL AND SPARK PLUG WIRES ARE ROUTED EXACTLY AS SPECIFIED IN TSB 18-48-98 TO ACHIEVE THE MOST BENEFIT. Inspect the Positive Crankcase Ventilation (PCV) valve. Shake the PCV valve to verify that the pintle inside of the PCV valve is free. Replace the PVC if the pintle is not free. If the intake manifold plenum pan gasket is leaking, an additional vacuum source will be created inside of the engine at the location of the pan gasket leakage. Engine combustion blow-by gases, oil vapor, and air from the crankcase filter/breather may be drawn past the leaking pan gasket and into the intake manifold. In most cases when this condition occurs, an engine at idle will create the highest vacuum and lowest amount of engine blow-by. 1. Allow the engine to reach normal operating temperature. 2. Stop the engine. 3. Disconnect the breather hose from the air cleaner. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1453 4. Attach a vacuum/pressure gauge to the end of the breather hose (Figure 1). 5. Disconnect the PCV valve hose from the intake manifold. 6. Seal off the intake manifold PCV valve hose port opening. 7. Seal off the open end of the PCV valve hose (Figure 2). NOTE: DURING THIS DIAGNOSIS, IT WOULD BE NORMAL FOR THE ENGINE TO DEVELOP PRESSURE WITHIN THE ENGINE CRANKCASE. THIS IS DUE TO THE NORMAL PROCESS OF EXHAUST BLOW-BY GASES LEAKING PAST THE ENGINE PISTON RINGS AND ACCUMULATING IN THE ENGINE CRANKCASE. DO NOT ALLOW MORE THAN 3 PSI (20.7 kpa) OF PRESSURE TO BUILD WITHIN THE ENGINE WHEN PERFORMING THE FOLLOWING DIAGNOSTIC PROCEDURE. 8. Start the warmed engine and observe the vacuum gauge. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1454 9. Allow the engine to idle for approximately 30 seconds. Do not allow more than 3 psi (20.7 kPa) of pressure to develop in the engine crankcase. 10. If the attached vacuum / pressure gauge does not indicate that a vacuum is present in the engine crankcase, then the intake manifold plenum pan gasket is good and no further internal engine vacuum leak diagnosis is required. 11. If an internal vacuum leak is present then perform the Repair Procedure. PARTS REQUIRED: For the 5.2L / 5.9L: 1 04897383AC Package, Intake Manifold Flange Gasket and Bolts 1 05017208AA Gasket, Intake Manifold Plenum Pan 15 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR) 04318001 Conditioner, Combustion Chamber For the 3.9L: 1 04897382AC Package, Intake Manifold Flange Gasket and Bolts 1 05017207AA Gasket, Intake Manifold Plenum Pan 14 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR)04318001 Conditioner, Combustion Chamber REPAIR PROCEDURE: 1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation instructions. NOTE: CLEAN ALL OIL RESIDUE FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND THE INTAKE MANIFOLD PLENUM CHAMBER. NOTE: THE PROPER BOLT TORQUE AND TIGHTENING SEQUENCE IS CRITICAL AND MUST BE FOLLOWED WHEN TIGHTENING BOTH THE PLENUM PAN BOLTS AND THE INTAKE MANIFOLD FLANGE BOLTS. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1455 3.9L Bolt Tightening Sequence and Torque Procedure: 3.9 Plenum Pan Bolt Torque Procedure 3.9 Intake Manifold Flange Bolt Torque Procedure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1456 5.2L / 5.9L Plenum Bolt Tightening Sequence and Torque Procedure: 5.2L / 5.9L Plenum Pan Bolt Torque Procedure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1457 5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure 2. With the engine reassembled, inspect the coil and spark plug wires for proper routing. Refer to TSB 09-48-98 for additional assistance. 3. Start the engine and allow it to warm to normal engine operating temperature. 4. Decarbon the combustion chamber using Mopar Combustion Chamber Conditioner (p/n 04318001) per the instructions. NOTE: ALLOW THE COMBUSTION CHAMBER CLEANER TO SOAK INSIDE OF THE ENGINE FOR 2 TO 2.5 HOURS. NOTE: A SECOND APPLICATION OF THE COMBUSTION CHAMBER CONDITIONER MAY BE REQUIRED IF THERE WAS A LARGE QUANTITY OF OIL LEAKAGE PAST THE INTAKE PLENUM PAN GASKET. 5. Verify proper engine oil level. POLICY: Reimbursable within the provisions of the warranty. Time Allowance FAILURE CODE: P8- New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption Intake Manifold Gasket: All Technical Service Bulletins Engine - Spark Knock/Oil Consumption NUMBER: 09-05-00 GROUP: Engine DATE: Feb.25, 2000 MODELS: 1994 - 1999 (AB) Ram Van 1994 - 1999 (AN) Dakota 1994 - 1999 (BRIBE) Ram Truck 1998 - 1999 (DN) Durango 1994 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-06-99, DATED SEP.10, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Spark Knock And Engine Oil Consumption Due To Intake Manifold Pan Gasket Oil Leak OVER VIEW: This bulletin involves the replacement of the engine intake manifold plenum pan gasket. NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH A 3.9L, 5.2L. OR 5.9L GASOLINE ENGINE. SYMPTOM/CONDITION: An engine intake manifold plenum pan gasket oil leak may occur on some V-6 and V-8 style engines. The oil leak is internal to the engine so no external oil leakage will be present. Two symptoms of this oil leak condition may be present. The vehicle operator may experience an engine spark knock during acceleration and/or an increase in the amount of engine oil consumed by the engine. DIAGNOSIS: Make sure Technical Service Bulletin (TSB) 18-48-98 has been performed. NOTE: IT IS IMPORTANT THAT THE COIL AND SPARK PLUG WIRES ARE ROUTED EXACTLY AS SPECIFIED IN TSB 18-48-98 TO ACHIEVE THE MOST BENEFIT. Inspect the Positive Crankcase Ventilation (PCV) valve. Shake the PCV valve to verify that the pintle inside of the PCV valve is free. Replace the PVC if the pintle is not free. If the intake manifold plenum pan gasket is leaking, an additional vacuum source will be created inside of the engine at the location of the pan gasket leakage. Engine combustion blow-by gases, oil vapor, and air from the crankcase filter/breather may be drawn past the leaking pan gasket and into the intake manifold. In most cases when this condition occurs, an engine at idle will create the highest vacuum and lowest amount of engine blow-by. 1. Allow the engine to reach normal operating temperature. 2. Stop the engine. 3. Disconnect the breather hose from the air cleaner. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1463 4. Attach a vacuum/pressure gauge to the end of the breather hose (Figure 1). 5. Disconnect the PCV valve hose from the intake manifold. 6. Seal off the intake manifold PCV valve hose port opening. 7. Seal off the open end of the PCV valve hose (Figure 2). NOTE: DURING THIS DIAGNOSIS, IT WOULD BE NORMAL FOR THE ENGINE TO DEVELOP PRESSURE WITHIN THE ENGINE CRANKCASE. THIS IS DUE TO THE NORMAL PROCESS OF EXHAUST BLOW-BY GASES LEAKING PAST THE ENGINE PISTON RINGS AND ACCUMULATING IN THE ENGINE CRANKCASE. DO NOT ALLOW MORE THAN 3 PSI (20.7 kpa) OF PRESSURE TO BUILD WITHIN THE ENGINE WHEN PERFORMING THE FOLLOWING DIAGNOSTIC PROCEDURE. 8. Start the warmed engine and observe the vacuum gauge. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1464 9. Allow the engine to idle for approximately 30 seconds. Do not allow more than 3 psi (20.7 kPa) of pressure to develop in the engine crankcase. 10. If the attached vacuum / pressure gauge does not indicate that a vacuum is present in the engine crankcase, then the intake manifold plenum pan gasket is good and no further internal engine vacuum leak diagnosis is required. 11. If an internal vacuum leak is present then perform the Repair Procedure. PARTS REQUIRED: For the 5.2L / 5.9L: 1 04897383AC Package, Intake Manifold Flange Gasket and Bolts 1 05017208AA Gasket, Intake Manifold Plenum Pan 15 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR) 04318001 Conditioner, Combustion Chamber For the 3.9L: 1 04897382AC Package, Intake Manifold Flange Gasket and Bolts 1 05017207AA Gasket, Intake Manifold Plenum Pan 14 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR)04318001 Conditioner, Combustion Chamber REPAIR PROCEDURE: 1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation instructions. NOTE: CLEAN ALL OIL RESIDUE FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND THE INTAKE MANIFOLD PLENUM CHAMBER. NOTE: THE PROPER BOLT TORQUE AND TIGHTENING SEQUENCE IS CRITICAL AND MUST BE FOLLOWED WHEN TIGHTENING BOTH THE PLENUM PAN BOLTS AND THE INTAKE MANIFOLD FLANGE BOLTS. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1465 3.9L Bolt Tightening Sequence and Torque Procedure: 3.9 Plenum Pan Bolt Torque Procedure 3.9 Intake Manifold Flange Bolt Torque Procedure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1466 5.2L / 5.9L Plenum Bolt Tightening Sequence and Torque Procedure: 5.2L / 5.9L Plenum Pan Bolt Torque Procedure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1467 5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure 2. With the engine reassembled, inspect the coil and spark plug wires for proper routing. Refer to TSB 09-48-98 for additional assistance. 3. Start the engine and allow it to warm to normal engine operating temperature. 4. Decarbon the combustion chamber using Mopar Combustion Chamber Conditioner (p/n 04318001) per the instructions. NOTE: ALLOW THE COMBUSTION CHAMBER CLEANER TO SOAK INSIDE OF THE ENGINE FOR 2 TO 2.5 HOURS. NOTE: A SECOND APPLICATION OF THE COMBUSTION CHAMBER CONDITIONER MAY BE REQUIRED IF THERE WAS A LARGE QUANTITY OF OIL LEAKAGE PAST THE INTAKE PLENUM PAN GASKET. 5. Verify proper engine oil level. POLICY: Reimbursable within the provisions of the warranty. Time Allowance FAILURE CODE: P8- New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Cylinder Head Off Valve Guide Seal: Service and Repair Cylinder Head Off Refer to Valves, Intake/Exhaust, Service and Repair for procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Cylinder Head Off > Page 1472 Valve Guide Seal: Service and Repair Cylinder Head On Refer to Valve Spring, Service and Repair for procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Component Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Component Locations > Page 1478 Oil Pressure Sending Unit/Switch, Camshaft Position Sensor Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1479 Oil Pressure Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams Engine Oil Pressure Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 1483 Oil Pressure Sensor: Description and Operation OIL PRESSURE SENSOR-PCM INPUT Sends a signal from the oil pressure sending unit to the Powertrain Control Module (PCM) relating to engine oil pressure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt ....................................................................................................................... .................................................... 68 Nm (50 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Measuring Timing Chain Stretch Timing Chain: Service and Repair Measuring Timing Chain Stretch NOTE: To access timing chain Refer to Timing Cover, Removal and Installation. 1. Place a scale next to the timing chain so that any movement of the chain may be measured. 2. Place a torque wrench and socket over camshaft sprocket attaching bolt. Apply torque in the direction of crankshaft rotation to take up slack; 41 Nm (30 ft. lbs.) torque with cylinder head installed or 20 Nm (15 ft. lbs.) torque with cylinder head removed. With a torque applied to the camshaft sprocket bolt, crankshaft should not be permitted to move. It may be necessary to block the crankshaft to prevent rotation. Measuring Timing Chain Wear And Stretch 3. Hold a scale with dimensional reading even with the edge of a chain link. With cylinder heads installed, apply 14 Nm (30 ft. lbs.) torque in the reverse direction. With the cylinder heads removed, apply 20 Nm (15 ft. lbs.) torque in the reverse direction. Note the amount of chain movement. 4. Install a new timing chain, if its movement exceeds 3.175 mm (1/8 inch). 5. If chain is not satisfactory, remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and camshaft sprockets. 6. Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores. 7. Place timing chain around both sprockets. 8. Turn crankshaft and camshaft to line up with keyway location in crankshaft sprocket and in camshaft sprocket. 9. Lift sprockets and chain (keep sprockets tight against the chain in position as described). Alignment Of Timing Marks 10. Slide both sprockets evenly over their respective shafts and use a straightedge to check alignment of timing marks. 11. Install the camshaft bolt. Tighten the bolt to 47 Nm (35 ft. lbs.) torque. 12. Check camshaft end play. The end play should be 0.051 - 0.152 mm (0.002 - 0.006 inch) with a new thrust plate and up to 0.254 min (0.010 inch) with a used thrust plate. If not within these limits install a new thrust plate. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Measuring Timing Chain Stretch > Page 1492 Timing Chain: Service and Repair Timing Chain Replacement REMOVAL 1. Disconnect battery negative cable. 2. Remove Timing Cover. Alignment Of Timing Marks 3. Re-install the vibration damper bolt finger tight. Using a suitable socket and breaker bar, rotate the crankshaft to align timing marks. 4. Remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and camshaft sprockets. INSTALLATION 1. Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores. 2. Place timing chain around both sprockets. 3. Turn crankshaft and camshaft to line up with keyway location in crankshaft sprocket and in camshaft sprocket. 4. Lift sprockets and chain (keep sprockets tight against the chain in position as described). 5. Slide both sprockets evenly over their respective shafts and use a straightedge to check alignment of timing marks. 6. Install the camshaft bolt. Tighten the bolt to 68 Nm (50 ft. lbs.) torque. 7. Check camshaft end play. The end play should be 0.051 - 0.152 mm (0.002 - 0.006 inch) with a new thrust plate and up to 0.254 mm (0.010 inch) with a used thrust plate. If not within these limits install a new thrust plate. 8. Install the timing chain cover. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications Automatic Belt Tensioner to Mounting Bracket Bolts 50 ft.lb Automatic Belt Tensioner to Block Bolts 30 ft.lb Autmatic Belt Tensioner Pulley Bolt 45 ft.lb Timing Chain Tensioner Bolts - 3.9L 210 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Chain Case Cover Bolts 30 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1499 Timing Cover: Service and Repair REMOVAL 1. Disconnect the negative cable from the battery. 2. Drain cooling system (refer to Cooling System). 3. Remove the serpentine belt (refer to Drive Belts, Mounts, Brackets and Accessories System). 4. Remove water pump (refer to Cooling System). 5. Remove power steering pump (refer to Steering and Suspension). 6. Remove vibration damper. 7. Loosen oil pan bolts and remove the front bolt at each side. 8. Remove the cover bolts. 9. Remove chain case cover and gasket using extreme caution to avoid damaging oil pan gasket. Removal Of Front Crankshaft Oil Seal 10. Place a suitable tool behind the lips of the oil seal to pry the oil seal outward. Be careful not to damage the crankshaft seal surface of cover. INSTALLATION 1. Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs. 2. The water pump mounting surface must be cleaned. 3. Using a new cover gasket, carefully install chain case cover to avoid damaging oil pan gasket. Use a small amount of Mopar(R) Silicone Rubber Adhesive Sealant, or equivalent, at the joint between timing chain cover gasket and the oil pan gasket. Finger tighten the timing chain cover bolts at this time. Placing Oil Seal On Installation Tool 6635 4. Place the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635. Seat the oil seal in the groove of the tool. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1500 Position Tool And Seal Onto Crankshaft 5. Position the seal and tool onto the crankshaft. 6. Tighten the 4 lower chain case cover bolts to 13 Nm (10 ft.lbs.) to prevent the cover from tipping during seal installation. Installing Oil Seal 7. Using the vibration damper bolt, tighten the bolt to draw the seal into position on the crankshaft. 8. Loosen the 4 bolts tightened in step 4 to allow realignment of front cover assembly. 9. Tighten chain case cover bolts to 41 Nm (30 ft.lbs.) torque. Tighten oil pan bolts to 24 Nm (215 inch lbs.) torque. 10. Remove the vibration damper bolt and seal installation tool. 11. Inspect the seal flange on the vibration damper. 12. Install vibration damper. 13. Install water pump and housing assembly using new gaskets (refer to Cooling System). Tighten bolts to 41 Nm (30 ft. lbs.) torque. 14. Install power steering pump (refer to Steering and Suspension). 15. Install the serpentine belt (refer to Drive Belts, Mounts, Brackets and Accessories System). 16. Install the cooling system fan. Tighten the bolts to 23 Nm (17 ft. lbs.) torque. 17. Position the fan shroud and install the bolts. Tighten the bolts to 11 Nm (95 inch lbs.) torque. 18. Fill cooling system (refer to Cooling System for the proper procedure). 19. Connect the negative cable to the battery. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Testing Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle ......................................................................................................................... ......................................................... 500 to 900 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1509 Idle Speed: Testing and Inspection The following test procedure has been developed to check throttle body calibrations for correct idle conditions. The procedure should be used to diagnose the throttle body for conditions that may cause idle problems. This procedure should be used only after normal diagnostic procedures have failed to produce results that indicate a throttle body related problem. Be sure to check for proper operation of the idle air control motor before performing this test. Fixed Orifice Tool A special fixed orifice tool (number 6714) must be used for the following test. 1. Start the engine and bring to operating temperature. Be sure all accessories are off before performing this test. 2. Shut off the engine and remove the air duct at throttle body. Install Orifice Tool 3. Disconnect the vacuum line at the PCV valve. 4. Install the 0.185 inch orifice tool (number 6714) into the disconnected vacuum line in place of the PCV valve. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1510 Idle Purge Line 5. Disconnect the idle purge vacuum line from fitting at throttle body. This vacuum line is located on the front of throttle body next to the MAP sensor. Cap the fitting at throttle body after vacuum line has been removed. 6. Connect the DRB scan tool to the 16-way data link connector. This connector is located under the instrument panel to the left of the steering column. Refer to the appropriate Powertrain Diagnostic Procedures service for DRB operation. 7. Start the engine and allow to warm up. 8. Using the DRB scan tool, scroll through the menus as follows: select-Stand Alone DRB III, select 1999 Diagnostics, select-Engine, select-System Test, select-Minimum Air Flow. 9. The DRB scan tool will count down to stabilize the idle rpm and display the minimum air flow idle rpm. The idle rpm should be between 500 and 900 rpm. If the idle speed is outside of these specifications, replace the throttle body. Refer to Throttle Body in the Component Removal/Installation. 10. Disconnect the DRB scan tool from the vehicle. 11. Remove cap from idle purge fitting at throttle body and install vacuum line. 12. Remove orifice tool and connect vacuum line to PCV valve. 13. Install air duct to throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Air Cleaner Housing Assembly 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 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Use following procedure if fuel rail is or is not equipped with fuel pressure test port. 1. Remove fuel fill cap. 2. The fuel filler tube contains a spring-loaded flap (door) located below fuel fill cap. The flap is used as a secondary way of sealing fuel tank if fuel fill cap has not been properly tightened. It is part of EVAP monitor system when vehicle is equipped with a Leak Detection Pump (LDP). The vehicle may be equipped with flap installed into fuel filler tube even though vehicle is not equipped with LDP and EVAP monitor system. Place a nonmetallic object into fuel fill tube and press on flap to relieve any tank pressure. 3. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. 6. 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. 7. Unplug connector from any injector. 8. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 9. Connect other end of jumper wire to positive side of battery. 10. 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. 11. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 12. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 13. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 14. Return fuel pump relay to PDC. 15. 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. Refer to Emission Control System. See On-Board Diagnostics. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1534 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1535 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1536 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1537 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1538 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1539 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1545 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1546 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1547 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1548 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1549 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1550 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1551 Ignition Cable: Specifications Spark Plug Cable Resistance Minimum 250 ohms 3000 ohms Maximum 1000 ohms 12000 ohms Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1552 Ignition Cable: Description and Operation Spark plug cables are sometimes referred to as secondary ignition wires. These cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1553 Ignition Cable: Testing and Inspection Check the spark plug cable connections for good contact at the coil(s), distributor cap towers, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, distributor and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean high voltage ignition cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. Head Shields On all engines, spark plug cable heat shields are pressed into the cylinder head to surround each spark plug cable boot and spark plug. These shields protect the spark plug boots from damage (due to intense engine heat generated by the exhaust manifolds) and should not be removed. After the spark plug cable has been installed, the lip of the cable boot should have a small air gap to the top of the heat shield. Testing When testing secondary cables for damage with an oscilloscope, follow the instructions of the equipment manufacturer. If an oscilloscope is not available, spark plug cables may be tested as follows: CAUTION: Do not leave any one spark plug cable disconnected for longer than necessary during testing. This may cause possible heat damage to the catalytic converter. Total test time must not exceed ten minutes. With the engine running, remove spark plug cable from spark plug (one at a time) and hold next to a good engine ground. If the cable and spark plug are in good condition, the engine rpm should drop and the engine will run poorly. If engine rpm does not drop, the cable and/or spark plug may not be operating properly and should be replaced. Also check engine cylinder compression. With the engine not running, connect one end of a test probe to a good ground. Start the engine and run the other end of the test probe along the entire length of all spark plug cables. If cables are cracked or punctured, there will be a noticeable spark jump from the damaged area to the test probe. The cable running from the ignition coil to the distributor cap can be checked in the same manner. Cracked, damaged or faulty cables should be replaced with resistance type cable. This can be identified by the words ELECTRONIC SUPPRESSION printed on the cable jacket. Use an ohmmeter to test for open circuits, excessive resistance or loose terminals. If equipped, remove the distributor cap from the distributor. Do not remove cables from cap. Remove cable from spark plug. Connect ohmmeter to spark plug terminal end of cable and to corresponding electrode in distributor cap. Resistance should be 250 to 1000 Ohms per inch of cable. If not, remove cable from distributor cap tower and connect ohmmeter to the terminal ends of cable. If resistance is not within specifications as found in the SPARK PLUG CABLE RESISTANCE chart, replace the cable. Test all spark plug cables in this manner. SPARK PLUG CABLE RESISTANCE MINIMUM = MAXIMUM 250 Ohms Per Inch = 1000 Ohms Per Inch 3000 Ohms Per Foot = 12,000 Ohms Per Foot Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1554 Ignition Cable: Service and Repair REMOVAL AND INSTALLATION Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. Engine Firing Order Install cables into the proper engine cylinder firing order. When replacing the spark plug and coil cables, route the cables correctly and secure in the proper retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause cross ignition of the plugs or short circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and the distributor cap tower. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Cap Inspection - External - Typical Cap Inspection-Internal-Typical Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the inside (caused by condensation entering the cap through cracks). Replace any cap that displays charred or eroded terminals. The machined surface of a terminal end (faces toward rotor) will indicate some evidence of erosion from normal operation. Examine the terminal ends for evidence of mechanical interference with the rotor tip. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Rotor Inspection - Typical Visually inspect the rotor for cracks, evidence of corrosion or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on the end of the metal tip. The silicone-dielectric- varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap 0.040 in Torque 30 ft lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1565 Spark Plug: Application and ID Plug Type ............................................................................................................................................ .................................................................... RC12LC4 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1566 Spark Plug: Description and Operation All engines use resistor type spark plugs. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Spark plugs that have low milage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Refer to the Spark Plug Condition. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1567 Spark Plug: Testing and Inspection SPARK PLUG CONDITIONS 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. Gap growth will not average more than approximately 0.025 mm (0.001 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. Oil Or Ash Encrusted Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1568 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. 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. Scavenger Deposits Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but this is a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy, but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and can be cleaned using standard procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1569 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. 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.) Spark Plug Overheating Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1570 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1571 Spark Plug: Service and Repair Heat Shields On all engines, spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. PLUG REMOVAL Cable Removal 1. Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result. 2. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. This will help prevent foreign material from entering the combustion chamber. 3. Remove the spark plug using a quality socket with a rubber or foam insert. 4. Inspect the spark plug condition. Refer to Spark Plug Condition in the Diagnostics and Testing. PLUG CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. PLUG GAP ADJUSTMENT Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1572 Setting Spark Plug Gap - Typical Check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode. Never attempt to adjust the gap by bending the center electrode. SPARK PLUG GAP 1.01 mm (0.040 in) PLUG INSTALLATION Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 35-41 Nm (26-30 ft. lbs.) torque. 3. Install spark plug cables over spark plugs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression should not be less than 689 kPa (100 psi) and not vary more than 172 kPa (25 psi) from cylinder to cylinder. If cylinder(s) have abnormally low compression pressures, repeat procedure. - If the same cylinder(s) repeat an abnormally low reading, it could indicate the existence of a problem in the cylinder. NOTE: The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should NOT be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1576 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST 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. (Refer to Powertrain Management for the correct procedure) 5. Disconnect the ignition coil. 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. Refer to Engine Specifications for the correct engine compression pressures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all times. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Mounting Bolts 30 ft.lb Water Pump Pulley 16 ft.lb Water Pump-to-Chain Case Cover Bolt 31 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1583 Water Pump: Description and Operation Reverse Rotating Water Pump-Typical 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 drive belt. The water pump impeller is pressed onto the rear of a shaft that rotates in a bearing pressed into the water pump body. The body has a small hole for ventilation. The water pump seals are lubricated by antifreeze in the coolant mixture. Additional lubrication is not necessary. A quick test to determine if pump is working is to check if heater warms properly. A defective water pump will not be able to circulate heated coolant through the long heater hose to the heater core, The water pump is bolted directly to the engine timing case/cover. A gasket is used as a seal between the water pump and timing chain case/cover. The water pump on all models can be removed without discharging the air conditioning system (if equipped). If water pump is replaced because of bearing/shaft damage, or leaking shaft seal, the mechanical cooling fan assembly should also be inspected. Inspect for fatigue cracks, loose blades, or loose rivets that could have resulted from excessive vibration. Replace fan if any of these conditions are found. Also check condition of the thermal Viscous Fan Drive. Refer to Fan Clutch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1584 Water Pump: Testing and Inspection Replace water pump assembly if it has any of the following conditions: ^ The body is cracked or damaged ^ Water leaks from shaft seal. This is evident by traces of coolant below vent hole ^ Loose or rough turning bearing. Also inspect viscous fan drive ^ Impeller rubs either the pump body or timing chain case/cover Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1585 Water Pump: Service and Repair REMOVAL The water pump can be removed and installed without discharging the air conditioning system (if equipped). 1. Disconnect battery negative cable. 2. Drain cooling system. 3. 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. 4. Remove upper radiator hose clamp and hose at radiator. Fan Blade And Viscous Fan Drive-3.9L/5.2L/5.9L Engines 5. The thermal viscous fan drive is attached (threaded) to the water pump hub shaft. Remove fan/viscous fan drive assembly from water pump by turning mounting nut counterclockwise as viewed from front. Threads on viscous fan drive are RIGHT HAND. A Snap-On 36 MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP) can be used. Place a bar or screwdriver between water pump pulley bolts to prevent pulley from rotating. Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time. 6. If water pump is being replaced, do not unbolt fan blade assembly from thermal viscous fan drive. 7. Remove fan shroud attaching hardware (two bolts at bottom-two clips at top). 8. Remove fan shroud and fan blade/viscous fan drive assembly from vehicle as a complete unit. 9. 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. 10. Do not remove water pump pulley bolts at this time. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1586 Automatic Belt Tensioner Assembly-3.9L/5.2L/5.9L Engines 11. Remove accessory drive belt as follows: The drive belt is equipped with a spring loaded automatic tensioner. Relax tension from belt by rotating tensioner clockwise (as viewed from front). When all belt tension has been relaxed, remove accessory drive belt. 12. Remove four water pump pulley-to-water pump hub bolts and remove pulley from vehicle. 13. Remove lower radiator hose clamp and remove lower hose at water pump. 14. Remove heater hose clamp and heater hose from heater hose coolant return tube. Coolant Return Tube-3.9L/5.2L/5.9L Engines-Typical 15. Loosen heater hose coolant return tube mounting bolt and remove tube from water pump. Discard the old tube O-ring. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1587 Water Pump Bolts-3.9L/5.2L/5.9L Engines 16. Remove seven water pump mounting bolts. 17. Loosen clamp at water pump end of bypass hose. Slip bypass hose from water pump while removing pump from vehicle. Discard old gasket. CAUTION: Do not pry water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks. INSTALLATION 1. Clean gasket mating surfaces. 2. Using a new gasket, install water pump to engine as follows: Guide water pump nipple into bypass hose as pump is being installed. Install water pump bolts. Tighten water pump mounting bolts to 40 Nm (30 ft. lbs.) torque. 3. Position bypass hose clamp to bypass hose. 4. Spin water pump to be sure that pump impeller does not rub against timing chain case/cover. 5. Install a new O-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. Be sure the slot in tube bracket is bottomed to mounting bolt. This will properly position return tube. 7. Connect radiator lower hose to water pump. 8. Connect heater hose and hose clamp to coolant return tube. 9. Install water pump pulley. Tighten bolts to 27 Nm (20 ft. lbs.) torque. Place a bar or screwdriver between water pump pulley bolts to prevent pulley from rotating. 10. Relax tension from belt tensioner. Install accessory drive belt. Belt Routing-3.9L/5.2L/5.9L Engines CAUTION: When installing the serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. For correct belt routing. The correct belt with correct length must be used. 11. Position fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1588 12. Install fan shroud. 13. Install fan blade/viscous fan drive assembly to water pump shaft. 14. Fill cooling system. 15. Connect battery negative cable. 16. Start and warm the engine. Check for leaks. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant ................................................................................................................................................ ............................................. 13.5 liters ( 14.3 quarts) NOTES: - Nominal refill capacities are shown. A variation may be observed from vehicle to vehicle due to manufacturing tolerances and refill procedures. - Capacities shown include vehicles with air conditioning and/or heavy-duty cooling systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1594 Coolant: Fluid Type Specifications The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37° C (-35° F). The antifreeze concentration must always be a minimum of 44%, year round, in all climates. If percentage is lower than 44%, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% antifreeze concentration, which prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. 100 Percent Ethylene-Glycol Should Not Be Used Use of 100 Percent Ethylene-Glycol will cause formation of additive deposits in the system, as the corrosive inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise as high as 149° C (300° F). this temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 % ethylene-glycol freezes at 22° C (-8° F). Propylene-Glycol Formulations Should Not Be Used Propylene-glycol formulations do not meet the required specifications. It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32° C (-26° F), 5 degrees higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257° F) at 96.5 kPa (14 PSI), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can result in boil-over and freeze up. Propylene-Glycol also has a poorer heat transfer characteristics than ethylene-glycol. This can increase cylinder head temperatures under certain conditions. Propylene-Glycol/Ethylene-Glycol Mixtures Should Not Be Used Propylene-glycol/ethylene-glycol mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the coling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining the freeze point will not be accurate. Both the refractive index and specific gravity differ between the ethylene-glycol and propylene-glycol. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 1595 Coolant: Service Precautions DO NOT mix green colored coolant with orange colored coolant. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 1596 Coolant: Description and Operation The cooling system is designed around the coolant. Coolant flows through the engine water jacket absorbing heat produced during engine operation. The coolant carries the heat to radiator and heater core. Here it is transferred to the ambient air passing through the radiator and heater core fins. The coolant also removes heat from the automatic transmission fluid in vehicles equipped with an automatic transmission. WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT RUNNING TEMPERATURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. CAUTION: Do not use straight antifreeze as engine coolant, inadequate engine running temperatures can result. Do not operate vehicle without proper concentration of recommended ethylene glycol coolant, high running temperatures and cooling system corrosion can result. The cooling system factory fill is a mixture of 50% Ethylene Glycol based antifreeze and 50% water. Using a suitable hydrometer, measure antifreeze concentration in the radiator when the engine is cool. If the cooling system has recently been serviced, allow coolant to circulate for at least 20 minutes before taking hydrometer reading. Properly mixed coolant will protect the cooling system to -37°C (-35°F). If the freeze protection is above -28°C (-20°F), drain enough coolant from the cooling system to allow room to add antifreeze to achieve adequate protection. Chrysler Corporation recommends Mopar(R) Antifreeze/Coolant or a high quality, ethylene glycol base antifreeze/coolant, with a silicate inhibitor. COOLANT PERFORMANCE ETHYLENE-GLYCOL MIXTURES The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37°C (-35°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. 100 Percent Ethylene-Glycol-Should Not Be Used in Chrysler Vehicles Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149°C (300)°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22°C (-8°F). Propylene-glycol Formulations-Should Not Be Used in Chrysler Vehicles Propylene-glycol formulations do not meet Chrysler coolant specifications. It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32°C (-26°F) 5 °C higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propyleneglycol is 125°C (257°F) at 96.5 kPa (14 psi), compared to 128°C (263 °F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up in Chrysler vehicles, which are designed for ethylene-glycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can increase cylinder head temperatures under certain conditions. Propylene-glycol/Ethylene-glycol Mixtures-Should Not Be Used in Chrysler Vehicles Propylene-glycol/Ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene glycol. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. COOLANT SELECTION AND ADDITIVES The presence of aluminum components in the cooling system requires strict corrosion protection. Maintain coolant at specified level with a mixture of ethylene-glycol based antifreeze and water. Chrysler Corporation recommends Mopar(R) Antifreeze or equivalent. If coolant becomes contaminated or looses color, drain and flush cooling system and fill with correctly mixed solution. A 0.25 percent emulsifiable oil is added to the radiator at the factory to prevent solder corrosion. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 1597 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Description and Operation Coolant Line/Hose: Description and Operation COOLING SYSTEM HOSES AND CLAMPS Radiator lower hoses are spring-reinforced to prevent collapse from water pump suction at moderate and high engine speeds. Inspect hoses at regular intervals. Replace hoses that are cracked, feel brittle when squeezed, or swell excessively when system is pressurized. The use of molded replacement hoses is recommended. When performing a hose inspection, inspect radiator lower hose for proper position and condition of spring. Hose Clamp Tool-Typical 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. Clamp Number/Letter Location 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation Coolant Reservoir: Description and Operation Coolant Reserve/Overflow System The coolant reserve/overflow system 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Page 1604 Coolant Reservoir: Service and Repair NOTE: Refer to Coolant Level Check-Service, Deaeration and Radiator Pressure Cap for coolant reserve/overflow system operation and service. Should the reserve/overflow tank become coated with corrosion or emulsifiable oil, it can be cleaned with detergent and water. Rinse tank thoroughly before refilling cooling system. REMOVAL 1. Remove battery positive and negative cables and battery. Coolant Recovery Bottle 2. Remove upper radiator closure panel. 3. Remove overflow hose at reserve/overflow tank. 4. Remove three (3) coolant recovery bottle screws and remove coolant recovery bottle from vehicle. INSTALLATION 1. Install coolant recovery bottle and three (3) Screws. 2. Install overflow hose to tank. 3. Install upper radiator closure panel. 4. Install battery. 5. Add coolant. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Description and Operation Radiator Cooling Fan Motor: Description and Operation Viscous clutch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Technical Service Bulletins > Customer Interest: > 07-03-99 > Nov > 99 > Engine - Overheats In High Ambient Temperatures. Technical Service Bulletin # 07-03-99 Date: 991105 Engine - Overheats In High Ambient Temperatures. NUMBER: 07-03-99 GROUP: Cooling DATE: Nov. 5, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-98, DATED NOV. 27, 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 CHANGES TO PART NUMBERS, CHANGES TO THE PROCEDURE, AND CHANGES TO THE TIME ALLOTTED TO PERFORM THE REPAIR. SUBJECT: Engine Overheats In High Ambient Temperatures OVERVIEW: This bulletin involves installing a revised fan, fan drive, and fan shroud. MODELS: 1998 - 1999 (DN) Durango SYMPTOM/CONDITION: Some Durangos may experience a high engine temperature condition (temperatures greater than 116°C. (240°F.)) when the vehicle is operated in stop-and-go traffic with ambient temperatures exceeding 32°C (90°F). The result from the high engine temperature may cause the following: ^ Engine Temperature Gauge To Read Higher Than Normal ^ Check Gauge Lamp To Illuminate ^ Warning Chime To Sound ^ Vehicles Equipped With Air Conditioning May Have The A/C System Disabled NOTE: THE POWERTRAIN CONTROL MODULE (PCM) IS DESIGNED TO DISABLE THE AIR CONDITIONING SYSTEM WHEN ENGINE TEMPERATURES EXCEED A PREDETERMINED VALUE AND/OR THE A/C HIGH SIDE PRESSURE EXCEEDS 470 P.S.I. +/- 20 P.S.I.. THIS IS A NORMAL CONDITION DESIGNED TO PROTECT THE ENGINE FROM OVERHEATING AND FROM DAMAGING THE AIC COMPRESSOR. ONCE THE ENGINE TEMPERATURE AND/OR A/C HIGH SIDE PRESSURE HAS LOWERED, THE PCM WILL TURN THE AIR CONDITIONING SYSTEM ON. DIAGNOSIS: 1. Examine the vehicle's cooling system for proper operation. The DRB III can be used to ensure that the engine temperature does not exceed 99° C (210° F) during normal operating conditions. If the engine temperature exceeds 99° C (210° F) during normal operating conditions, the cooling system must be inspected and repaired. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), pages 7-9 through 7-20 for information regarding Cooling System Diagnosis And Testing. NOTE: THIS BULLETIN ADDRESSES ENGINE OVERHEAT CONDITIONS THAT OCCURS ONLY IN STOP-AND-GO TRAFFIC WITH AMBIENT TEMPERATURES EXCEEDING 32aC (90°F). 2. If the vehicle's cooling system is operating normally and the customer identities that the vehicle exhibited the previously stated SYMPTOM/CONDITION, perform the Repair Procedure. PARTS REQUIRED: 1 52027709 Fan, Cooling 1 52029767AA Drive, Fan AR (1) **52029012AD** Shroud, Fan, Four Wheel Drive AR (1) **52028614AC** Shroud, Fan, Two Wheel Drive POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Technical Service Bulletins > Customer Interest: > 07-03-99 > Nov > 99 > Engine - Overheats In High Ambient Temperatures. > Page 1617 Labor Operation No: 07-20-01-94 **0.5 Hrs.** FAILURE CODE: P8 - New Part 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. Disconnect and isolate the battery negative cable. 2. The thermal viscous fan drive/fan blade assembly is attached (threaded) to the water pump hub shaft. Remove the fan blade/viscous fan drive assembly from the water pump by turning the attaching nut counterclockwise as viewed from the front of the vehicle. Threads on the viscous fan drive are RIGHT HANDED. A Snap-on 36 mm fan wrench (Snap-on number SP346 from Cummins Diesel Tool Set (Snap-on number 2017DSP)) can be used. The water pump pulley can be held in place by one of the two following methods based upon whether the water pump pulley is pressed onto the water pump or held in place with four attachment bolts. ^ Pressed-On Water Pump Pulley The water pump pulley can be held in place by using Spanner Wrench (Special Tool 6958) and Adapter Pins (Special Tool 8346). ^ Bolt-On Water Pump Pulley Place a bar or screwdriver between the water pump pulley bolts to prevent the pulley from rotating. 3. Remove the four fan shroud bolts securing the shroud to the radiator. 4. Remove the fan shroud and fan blade/viscous fan drive assembly as a complete unit from the vehicle. 5. Remove the four bolts attaching the fan blade to the viscous fan drive. 6. To allow for adjustment of the **revised** fan shroud, drill the **revised upper fan shroud (see Parts Required section)** attachment holes to 15 mm (0.59 in.). 7. Attach the fan blade p/n 52027709 to the revised viscous fan drive p/n 52029767AA using the four bolts removed from the old assembly. Tighten the bolts to 23 N-m (17 ft. lbs.). 8. Position the fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit. 9. Install the **revised** fan shroud onto the radiator leaving the attachment bolts loose. 10. Install the fan blade/viscous fan drive assembly onto the water pump shaft. Tighten the nut to 27 N.m (20 ft. lbs.). 11. Rotate the fan by hand to ensure no contact between the fan blade and the fan shroud. Adjust the position of the fan shroud so that the clearance between the fan blades and the fan shroud are equal throughout the circumference of the shroud and there is 8 mm (0.30 in.) of clearance between the fan blades and the fan shroud. The fan shroud attachment holes can be enlarged even further if necessary to achieve proper clearance as long as the fan shroud bolts continue to have an adequate clamping surface. Tighten the fan shroud bolts. 12. Connect the battery negative cable and reset the clock. 13. Start the engine. Firmly apply the service brakes and put the transmission into "D". Perform a "brake torque" check to ensure that the engine motion does not cause the fan blades to come in contact with the fan shroud. 14. Perform the same test but with the transmission in "R". 15. If the fan blades came in contact with the fan shroud at any time during the previous two tests, readjust the fan shroud as necessary. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fan Blade: > 07-03-99 > Nov > 99 > Engine - Overheats In High Ambient Temperatures. Technical Service Bulletin # 07-03-99 Date: 991105 Engine - Overheats In High Ambient Temperatures. NUMBER: 07-03-99 GROUP: Cooling DATE: Nov. 5, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-98, DATED NOV. 27, 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 CHANGES TO PART NUMBERS, CHANGES TO THE PROCEDURE, AND CHANGES TO THE TIME ALLOTTED TO PERFORM THE REPAIR. SUBJECT: Engine Overheats In High Ambient Temperatures OVERVIEW: This bulletin involves installing a revised fan, fan drive, and fan shroud. MODELS: 1998 - 1999 (DN) Durango SYMPTOM/CONDITION: Some Durangos may experience a high engine temperature condition (temperatures greater than 116°C. (240°F.)) when the vehicle is operated in stop-and-go traffic with ambient temperatures exceeding 32°C (90°F). The result from the high engine temperature may cause the following: ^ Engine Temperature Gauge To Read Higher Than Normal ^ Check Gauge Lamp To Illuminate ^ Warning Chime To Sound ^ Vehicles Equipped With Air Conditioning May Have The A/C System Disabled NOTE: THE POWERTRAIN CONTROL MODULE (PCM) IS DESIGNED TO DISABLE THE AIR CONDITIONING SYSTEM WHEN ENGINE TEMPERATURES EXCEED A PREDETERMINED VALUE AND/OR THE A/C HIGH SIDE PRESSURE EXCEEDS 470 P.S.I. +/- 20 P.S.I.. THIS IS A NORMAL CONDITION DESIGNED TO PROTECT THE ENGINE FROM OVERHEATING AND FROM DAMAGING THE AIC COMPRESSOR. ONCE THE ENGINE TEMPERATURE AND/OR A/C HIGH SIDE PRESSURE HAS LOWERED, THE PCM WILL TURN THE AIR CONDITIONING SYSTEM ON. DIAGNOSIS: 1. Examine the vehicle's cooling system for proper operation. The DRB III can be used to ensure that the engine temperature does not exceed 99° C (210° F) during normal operating conditions. If the engine temperature exceeds 99° C (210° F) during normal operating conditions, the cooling system must be inspected and repaired. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), pages 7-9 through 7-20 for information regarding Cooling System Diagnosis And Testing. NOTE: THIS BULLETIN ADDRESSES ENGINE OVERHEAT CONDITIONS THAT OCCURS ONLY IN STOP-AND-GO TRAFFIC WITH AMBIENT TEMPERATURES EXCEEDING 32aC (90°F). 2. If the vehicle's cooling system is operating normally and the customer identities that the vehicle exhibited the previously stated SYMPTOM/CONDITION, perform the Repair Procedure. PARTS REQUIRED: 1 52027709 Fan, Cooling 1 52029767AA Drive, Fan AR (1) **52029012AD** Shroud, Fan, Four Wheel Drive AR (1) **52028614AC** Shroud, Fan, Two Wheel Drive POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fan Blade: > 07-03-99 > Nov > 99 > Engine - Overheats In High Ambient Temperatures. > Page 1623 Labor Operation No: 07-20-01-94 **0.5 Hrs.** FAILURE CODE: P8 - New Part 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. Disconnect and isolate the battery negative cable. 2. The thermal viscous fan drive/fan blade assembly is attached (threaded) to the water pump hub shaft. Remove the fan blade/viscous fan drive assembly from the water pump by turning the attaching nut counterclockwise as viewed from the front of the vehicle. Threads on the viscous fan drive are RIGHT HANDED. A Snap-on 36 mm fan wrench (Snap-on number SP346 from Cummins Diesel Tool Set (Snap-on number 2017DSP)) can be used. The water pump pulley can be held in place by one of the two following methods based upon whether the water pump pulley is pressed onto the water pump or held in place with four attachment bolts. ^ Pressed-On Water Pump Pulley The water pump pulley can be held in place by using Spanner Wrench (Special Tool 6958) and Adapter Pins (Special Tool 8346). ^ Bolt-On Water Pump Pulley Place a bar or screwdriver between the water pump pulley bolts to prevent the pulley from rotating. 3. Remove the four fan shroud bolts securing the shroud to the radiator. 4. Remove the fan shroud and fan blade/viscous fan drive assembly as a complete unit from the vehicle. 5. Remove the four bolts attaching the fan blade to the viscous fan drive. 6. To allow for adjustment of the **revised** fan shroud, drill the **revised upper fan shroud (see Parts Required section)** attachment holes to 15 mm (0.59 in.). 7. Attach the fan blade p/n 52027709 to the revised viscous fan drive p/n 52029767AA using the four bolts removed from the old assembly. Tighten the bolts to 23 N-m (17 ft. lbs.). 8. Position the fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit. 9. Install the **revised** fan shroud onto the radiator leaving the attachment bolts loose. 10. Install the fan blade/viscous fan drive assembly onto the water pump shaft. Tighten the nut to 27 N.m (20 ft. lbs.). 11. Rotate the fan by hand to ensure no contact between the fan blade and the fan shroud. Adjust the position of the fan shroud so that the clearance between the fan blades and the fan shroud are equal throughout the circumference of the shroud and there is 8 mm (0.30 in.) of clearance between the fan blades and the fan shroud. The fan shroud attachment holes can be enlarged even further if necessary to achieve proper clearance as long as the fan shroud bolts continue to have an adequate clamping surface. Tighten the fan shroud bolts. 12. Connect the battery negative cable and reset the clock. 13. Start the engine. Firmly apply the service brakes and put the transmission into "D". Perform a "brake torque" check to ensure that the engine motion does not cause the fan blades to come in contact with the fan shroud. 14. Perform the same test but with the transmission in "R". 15. If the fan blades came in contact with the fan shroud at any time during the previous two tests, readjust the fan shroud as necessary. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fan Blade: > 07-05-98 > Sep > 98 > Engine Cooling Fan - Roaring Noise Explanation Fan Blade: All Technical Service Bulletins Engine Cooling Fan - Roaring Noise Explanation NO: 07-05-98 GROUP: Cooling DATE: Sep. 4, 1998 SUBJECT: Engine Cooling Fan Noise MODELS: 1998 - 1999 (AB) Ram Van/Wagon 1997 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango DISCUSSION: Some vehicles may exhibit an engine cooling fan "roar" noise. This noise is created by a large cooling fan that is required to provide optimum cooling for low vehicle speed operation in hot weather conditions and for heavy trailer towing. Since the large cooling fan is unnecessary in most operating conditions, these vehicles are also equipped with viscous fan drives that allow the fan to operate at variable speeds based upon temperature loads. The viscous fan drive will engage the fan for maximum cooling when temperatures are high and allow the fan to operate at slower speeds when temperatures are low. In addition, at engine start-up, the viscous fan drive engages the fan for maximum cooling until the fluid in the viscous clutch can dissipate out of the clutch drive grooves allowing the fan to operate at a slower speed. Because of the viscous fan drive, the noise may occur during high temperature conditions and for the first 1-2 minutes of operation. Due to the roar of the fan, customers may also complain of a perceived loss of power, automatic transmission slippage, or that the transmission is slaying into a low gear too long (delayed upshift). Customers concerned about this noise should be advised that this condition is normal and no repair attempts should be made. POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fan Blade: > 07-05-98 > Sep > 98 > Engine Cooling Fan - Roaring Noise Explanation Fan Blade: All Technical Service Bulletins Engine Cooling Fan - Roaring Noise Explanation NO: 07-05-98 GROUP: Cooling DATE: Sep. 4, 1998 SUBJECT: Engine Cooling Fan Noise MODELS: 1998 - 1999 (AB) Ram Van/Wagon 1997 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango DISCUSSION: Some vehicles may exhibit an engine cooling fan "roar" noise. This noise is created by a large cooling fan that is required to provide optimum cooling for low vehicle speed operation in hot weather conditions and for heavy trailer towing. Since the large cooling fan is unnecessary in most operating conditions, these vehicles are also equipped with viscous fan drives that allow the fan to operate at variable speeds based upon temperature loads. The viscous fan drive will engage the fan for maximum cooling when temperatures are high and allow the fan to operate at slower speeds when temperatures are low. In addition, at engine start-up, the viscous fan drive engages the fan for maximum cooling until the fluid in the viscous clutch can dissipate out of the clutch drive grooves allowing the fan to operate at a slower speed. Because of the viscous fan drive, the noise may occur during high temperature conditions and for the first 1-2 minutes of operation. Due to the roar of the fan, customers may also complain of a perceived loss of power, automatic transmission slippage, or that the transmission is slaying into a low gear too long (delayed upshift). Customers concerned about this noise should be advised that this condition is normal and no repair attempts should be made. POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Technical Service Bulletins > Page 1633 Fan Blade: Service and Repair The fan blades cannot be repaired. If fan is damaged, it must be replaced. Inspect fan as follows: 1. Remove fan blade and viscous fan drive as an assembly from the engine. 2. Remove fan blade assembly from viscous fan drive unit (four bolts). 3. 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. WARNING: DO NOT ATTEMPT TO BEND OR STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN SPECIFICATIONS. 4. Inspect fan assembly for cracks, bends, loose rivets or broken welds. Replace fan if any damage is found. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Customer Interest: > 07-03-99 > Nov > 99 > Engine - Overheats In High Ambient Temperatures. Technical Service Bulletin # 07-03-99 Date: 991105 Engine - Overheats In High Ambient Temperatures. NUMBER: 07-03-99 GROUP: Cooling DATE: Nov. 5, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-98, DATED NOV. 27, 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 CHANGES TO PART NUMBERS, CHANGES TO THE PROCEDURE, AND CHANGES TO THE TIME ALLOTTED TO PERFORM THE REPAIR. SUBJECT: Engine Overheats In High Ambient Temperatures OVERVIEW: This bulletin involves installing a revised fan, fan drive, and fan shroud. MODELS: 1998 - 1999 (DN) Durango SYMPTOM/CONDITION: Some Durangos may experience a high engine temperature condition (temperatures greater than 116°C. (240°F.)) when the vehicle is operated in stop-and-go traffic with ambient temperatures exceeding 32°C (90°F). The result from the high engine temperature may cause the following: ^ Engine Temperature Gauge To Read Higher Than Normal ^ Check Gauge Lamp To Illuminate ^ Warning Chime To Sound ^ Vehicles Equipped With Air Conditioning May Have The A/C System Disabled NOTE: THE POWERTRAIN CONTROL MODULE (PCM) IS DESIGNED TO DISABLE THE AIR CONDITIONING SYSTEM WHEN ENGINE TEMPERATURES EXCEED A PREDETERMINED VALUE AND/OR THE A/C HIGH SIDE PRESSURE EXCEEDS 470 P.S.I. +/- 20 P.S.I.. THIS IS A NORMAL CONDITION DESIGNED TO PROTECT THE ENGINE FROM OVERHEATING AND FROM DAMAGING THE AIC COMPRESSOR. ONCE THE ENGINE TEMPERATURE AND/OR A/C HIGH SIDE PRESSURE HAS LOWERED, THE PCM WILL TURN THE AIR CONDITIONING SYSTEM ON. DIAGNOSIS: 1. Examine the vehicle's cooling system for proper operation. The DRB III can be used to ensure that the engine temperature does not exceed 99° C (210° F) during normal operating conditions. If the engine temperature exceeds 99° C (210° F) during normal operating conditions, the cooling system must be inspected and repaired. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), pages 7-9 through 7-20 for information regarding Cooling System Diagnosis And Testing. NOTE: THIS BULLETIN ADDRESSES ENGINE OVERHEAT CONDITIONS THAT OCCURS ONLY IN STOP-AND-GO TRAFFIC WITH AMBIENT TEMPERATURES EXCEEDING 32aC (90°F). 2. If the vehicle's cooling system is operating normally and the customer identities that the vehicle exhibited the previously stated SYMPTOM/CONDITION, perform the Repair Procedure. PARTS REQUIRED: 1 52027709 Fan, Cooling 1 52029767AA Drive, Fan AR (1) **52029012AD** Shroud, Fan, Four Wheel Drive AR (1) **52028614AC** Shroud, Fan, Two Wheel Drive POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Customer Interest: > 07-03-99 > Nov > 99 > Engine - Overheats In High Ambient Temperatures. > Page 1642 Labor Operation No: 07-20-01-94 **0.5 Hrs.** FAILURE CODE: P8 - New Part 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. Disconnect and isolate the battery negative cable. 2. The thermal viscous fan drive/fan blade assembly is attached (threaded) to the water pump hub shaft. Remove the fan blade/viscous fan drive assembly from the water pump by turning the attaching nut counterclockwise as viewed from the front of the vehicle. Threads on the viscous fan drive are RIGHT HANDED. A Snap-on 36 mm fan wrench (Snap-on number SP346 from Cummins Diesel Tool Set (Snap-on number 2017DSP)) can be used. The water pump pulley can be held in place by one of the two following methods based upon whether the water pump pulley is pressed onto the water pump or held in place with four attachment bolts. ^ Pressed-On Water Pump Pulley The water pump pulley can be held in place by using Spanner Wrench (Special Tool 6958) and Adapter Pins (Special Tool 8346). ^ Bolt-On Water Pump Pulley Place a bar or screwdriver between the water pump pulley bolts to prevent the pulley from rotating. 3. Remove the four fan shroud bolts securing the shroud to the radiator. 4. Remove the fan shroud and fan blade/viscous fan drive assembly as a complete unit from the vehicle. 5. Remove the four bolts attaching the fan blade to the viscous fan drive. 6. To allow for adjustment of the **revised** fan shroud, drill the **revised upper fan shroud (see Parts Required section)** attachment holes to 15 mm (0.59 in.). 7. Attach the fan blade p/n 52027709 to the revised viscous fan drive p/n 52029767AA using the four bolts removed from the old assembly. Tighten the bolts to 23 N-m (17 ft. lbs.). 8. Position the fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit. 9. Install the **revised** fan shroud onto the radiator leaving the attachment bolts loose. 10. Install the fan blade/viscous fan drive assembly onto the water pump shaft. Tighten the nut to 27 N.m (20 ft. lbs.). 11. Rotate the fan by hand to ensure no contact between the fan blade and the fan shroud. Adjust the position of the fan shroud so that the clearance between the fan blades and the fan shroud are equal throughout the circumference of the shroud and there is 8 mm (0.30 in.) of clearance between the fan blades and the fan shroud. The fan shroud attachment holes can be enlarged even further if necessary to achieve proper clearance as long as the fan shroud bolts continue to have an adequate clamping surface. Tighten the fan shroud bolts. 12. Connect the battery negative cable and reset the clock. 13. Start the engine. Firmly apply the service brakes and put the transmission into "D". Perform a "brake torque" check to ensure that the engine motion does not cause the fan blades to come in contact with the fan shroud. 14. Perform the same test but with the transmission in "R". 15. If the fan blades came in contact with the fan shroud at any time during the previous two tests, readjust the fan shroud as necessary. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fan Clutch: > 07-03-99 > Nov > 99 > Engine - Overheats In High Ambient Temperatures. Technical Service Bulletin # 07-03-99 Date: 991105 Engine - Overheats In High Ambient Temperatures. NUMBER: 07-03-99 GROUP: Cooling DATE: Nov. 5, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-98, DATED NOV. 27, 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 CHANGES TO PART NUMBERS, CHANGES TO THE PROCEDURE, AND CHANGES TO THE TIME ALLOTTED TO PERFORM THE REPAIR. SUBJECT: Engine Overheats In High Ambient Temperatures OVERVIEW: This bulletin involves installing a revised fan, fan drive, and fan shroud. MODELS: 1998 - 1999 (DN) Durango SYMPTOM/CONDITION: Some Durangos may experience a high engine temperature condition (temperatures greater than 116°C. (240°F.)) when the vehicle is operated in stop-and-go traffic with ambient temperatures exceeding 32°C (90°F). The result from the high engine temperature may cause the following: ^ Engine Temperature Gauge To Read Higher Than Normal ^ Check Gauge Lamp To Illuminate ^ Warning Chime To Sound ^ Vehicles Equipped With Air Conditioning May Have The A/C System Disabled NOTE: THE POWERTRAIN CONTROL MODULE (PCM) IS DESIGNED TO DISABLE THE AIR CONDITIONING SYSTEM WHEN ENGINE TEMPERATURES EXCEED A PREDETERMINED VALUE AND/OR THE A/C HIGH SIDE PRESSURE EXCEEDS 470 P.S.I. +/- 20 P.S.I.. THIS IS A NORMAL CONDITION DESIGNED TO PROTECT THE ENGINE FROM OVERHEATING AND FROM DAMAGING THE AIC COMPRESSOR. ONCE THE ENGINE TEMPERATURE AND/OR A/C HIGH SIDE PRESSURE HAS LOWERED, THE PCM WILL TURN THE AIR CONDITIONING SYSTEM ON. DIAGNOSIS: 1. Examine the vehicle's cooling system for proper operation. The DRB III can be used to ensure that the engine temperature does not exceed 99° C (210° F) during normal operating conditions. If the engine temperature exceeds 99° C (210° F) during normal operating conditions, the cooling system must be inspected and repaired. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), pages 7-9 through 7-20 for information regarding Cooling System Diagnosis And Testing. NOTE: THIS BULLETIN ADDRESSES ENGINE OVERHEAT CONDITIONS THAT OCCURS ONLY IN STOP-AND-GO TRAFFIC WITH AMBIENT TEMPERATURES EXCEEDING 32aC (90°F). 2. If the vehicle's cooling system is operating normally and the customer identities that the vehicle exhibited the previously stated SYMPTOM/CONDITION, perform the Repair Procedure. PARTS REQUIRED: 1 52027709 Fan, Cooling 1 52029767AA Drive, Fan AR (1) **52029012AD** Shroud, Fan, Four Wheel Drive AR (1) **52028614AC** Shroud, Fan, Two Wheel Drive POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fan Clutch: > 07-03-99 > Nov > 99 > Engine - Overheats In High Ambient Temperatures. > Page 1648 Labor Operation No: 07-20-01-94 **0.5 Hrs.** FAILURE CODE: P8 - New Part 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. Disconnect and isolate the battery negative cable. 2. The thermal viscous fan drive/fan blade assembly is attached (threaded) to the water pump hub shaft. Remove the fan blade/viscous fan drive assembly from the water pump by turning the attaching nut counterclockwise as viewed from the front of the vehicle. Threads on the viscous fan drive are RIGHT HANDED. A Snap-on 36 mm fan wrench (Snap-on number SP346 from Cummins Diesel Tool Set (Snap-on number 2017DSP)) can be used. The water pump pulley can be held in place by one of the two following methods based upon whether the water pump pulley is pressed onto the water pump or held in place with four attachment bolts. ^ Pressed-On Water Pump Pulley The water pump pulley can be held in place by using Spanner Wrench (Special Tool 6958) and Adapter Pins (Special Tool 8346). ^ Bolt-On Water Pump Pulley Place a bar or screwdriver between the water pump pulley bolts to prevent the pulley from rotating. 3. Remove the four fan shroud bolts securing the shroud to the radiator. 4. Remove the fan shroud and fan blade/viscous fan drive assembly as a complete unit from the vehicle. 5. Remove the four bolts attaching the fan blade to the viscous fan drive. 6. To allow for adjustment of the **revised** fan shroud, drill the **revised upper fan shroud (see Parts Required section)** attachment holes to 15 mm (0.59 in.). 7. Attach the fan blade p/n 52027709 to the revised viscous fan drive p/n 52029767AA using the four bolts removed from the old assembly. Tighten the bolts to 23 N-m (17 ft. lbs.). 8. Position the fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit. 9. Install the **revised** fan shroud onto the radiator leaving the attachment bolts loose. 10. Install the fan blade/viscous fan drive assembly onto the water pump shaft. Tighten the nut to 27 N.m (20 ft. lbs.). 11. Rotate the fan by hand to ensure no contact between the fan blade and the fan shroud. Adjust the position of the fan shroud so that the clearance between the fan blades and the fan shroud are equal throughout the circumference of the shroud and there is 8 mm (0.30 in.) of clearance between the fan blades and the fan shroud. The fan shroud attachment holes can be enlarged even further if necessary to achieve proper clearance as long as the fan shroud bolts continue to have an adequate clamping surface. Tighten the fan shroud bolts. 12. Connect the battery negative cable and reset the clock. 13. Start the engine. Firmly apply the service brakes and put the transmission into "D". Perform a "brake torque" check to ensure that the engine motion does not cause the fan blades to come in contact with the fan shroud. 14. Perform the same test but with the transmission in "R". 15. If the fan blades came in contact with the fan shroud at any time during the previous two tests, readjust the fan shroud as necessary. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fan Clutch: > 07-05-98 > Sep > 98 > Engine Cooling Fan - Roaring Noise Explanation Fan Clutch: All Technical Service Bulletins Engine Cooling Fan - Roaring Noise Explanation NO: 07-05-98 GROUP: Cooling DATE: Sep. 4, 1998 SUBJECT: Engine Cooling Fan Noise MODELS: 1998 - 1999 (AB) Ram Van/Wagon 1997 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango DISCUSSION: Some vehicles may exhibit an engine cooling fan "roar" noise. This noise is created by a large cooling fan that is required to provide optimum cooling for low vehicle speed operation in hot weather conditions and for heavy trailer towing. Since the large cooling fan is unnecessary in most operating conditions, these vehicles are also equipped with viscous fan drives that allow the fan to operate at variable speeds based upon temperature loads. The viscous fan drive will engage the fan for maximum cooling when temperatures are high and allow the fan to operate at slower speeds when temperatures are low. In addition, at engine start-up, the viscous fan drive engages the fan for maximum cooling until the fluid in the viscous clutch can dissipate out of the clutch drive grooves allowing the fan to operate at a slower speed. Because of the viscous fan drive, the noise may occur during high temperature conditions and for the first 1-2 minutes of operation. Due to the roar of the fan, customers may also complain of a perceived loss of power, automatic transmission slippage, or that the transmission is slaying into a low gear too long (delayed upshift). Customers concerned about this noise should be advised that this condition is normal and no repair attempts should be made. POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fan Clutch: > 07-05-98 > Sep > 98 > Engine Cooling Fan - Roaring Noise Explanation Fan Clutch: All Technical Service Bulletins Engine Cooling Fan - Roaring Noise Explanation NO: 07-05-98 GROUP: Cooling DATE: Sep. 4, 1998 SUBJECT: Engine Cooling Fan Noise MODELS: 1998 - 1999 (AB) Ram Van/Wagon 1997 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango DISCUSSION: Some vehicles may exhibit an engine cooling fan "roar" noise. This noise is created by a large cooling fan that is required to provide optimum cooling for low vehicle speed operation in hot weather conditions and for heavy trailer towing. Since the large cooling fan is unnecessary in most operating conditions, these vehicles are also equipped with viscous fan drives that allow the fan to operate at variable speeds based upon temperature loads. The viscous fan drive will engage the fan for maximum cooling when temperatures are high and allow the fan to operate at slower speeds when temperatures are low. In addition, at engine start-up, the viscous fan drive engages the fan for maximum cooling until the fluid in the viscous clutch can dissipate out of the clutch drive grooves allowing the fan to operate at a slower speed. Because of the viscous fan drive, the noise may occur during high temperature conditions and for the first 1-2 minutes of operation. Due to the roar of the fan, customers may also complain of a perceived loss of power, automatic transmission slippage, or that the transmission is slaying into a low gear too long (delayed upshift). Customers concerned about this noise should be advised that this condition is normal and no repair attempts should be made. POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Page 1658 Fan Clutch: Description and Operation Fan Blade/Viscous Fan Drive-3.9L/5.2L/5.9L Engine Viscous Fan Drive-3.9L/5.2L/5.9L Engine-Typical The thermal viscous fan drive is a silicone-fluid- filled coupling used to connect the fan blades to the water pump shaft. The coupling allows the fan to be driven in a normal manner. This is done at low engine speeds while limiting the top speed of the fan to a predetermined maximum level at higher engine speeds. A thermostatic bimetallic spring coil is located on the front face of the viscous fan drive unit. This spring coil reacts to the temperature of the radiator discharge air, It engages the viscous fan drive for higher fan speed if the air temperature from the radiator rises above a certain point. Until additional engine cooling is necessary, the fan will remain at a reduced rpm regardless of engine speed. Only when sufficient heat is present, will the viscous fan drive engage. This is when the air flowing through the radiator core causes a reaction to the bimetallic coil. It then increases fan speed to provide the necessary additional engine cooling. Once the engine has cooled, the radiator discharge temperature will drop. The bimetallic coil again reacts and the fan speed is reduced to the previous disengaged speed. CAUTION: Engines equipped with accessory drive belts have reverse rotating fans and viscous fan drives. They are marked with the word REVERSE to designate their usage. Installation of the wrong fan or viscous fan drive can result in engine overheating. CAUTION: If the viscous fan drive is replaced because of mechanical damage, the cooling fan blades should also be inspected. Inspect for fatigue cracks, loose blades, or loose rivets that could have resulted from excessive vibration. Replace fan blade assembly if any of these conditions are found. Also inspect water pump bearing and shaft assembly for any related damage due to a viscous fan drive malfunction. NOISE Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Page 1659 NOTE: It is normal for fan noise to be louder (roaring) when: ^ The underhood temperature is above the engagement point for the viscous drive coupling. This may occur when ambient (outside air temperature) is very high. ^ Engine loads and temperatures are high such as when towing a trailer. ^ Cool silicone fluid within the fan drive unit is being redistributed back to its normal disengaged (warm) position. This can occur during the first 15 seconds to one minute after engine start-up on a cold engine. LEAKS Viscous fan drive operation is not affected by small oil stains near the drive bearing. If leakage appears excessive, replace the fan drive unit. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Page 1660 Fan Clutch: Testing and Inspection If the fan assembly free-wheels without drag (the fan blades will revolve more than five turns when spun by hand), replace the fan drive. This spin test must be performed when the engine is cool. For the following test, the cooling system must be in good condition. It also will ensure against excessively high coolant temperature. WARNING: BE SURE THAT THERE IS ADEQUATE FAN BLADE CLEARANCE BEFORE DRILLING. 1. Drill a 3.18-mm (1/8-inch) diameter hole in the top center of the fan shroud. 2. Obtain a dial thermometer with an 8 inch stem (or equivalent). It should have a range of -18° to 105°C (0° to 220°F). Insert thermometer through the hole in the shroud. Be sure that there is adequate clearance from the fan blades. 3. Connect a tachometer and an engine ignition timing light (timing light is to be used as a strobe light). 4. Block the air flow through the radiator. Secure a sheet of plastic in front of the radiator (or air conditioner condenser). Use tape at the top to secure the plastic and be sure that the air flow is blocked. 5. Be sure that the air conditioner (if equipped) is turned off. 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 FAN. DO NOT WEAR LOOSE CLOTHING. 6. Start the engine and operate at 2400 rpm. Within ten minutes the air temperature (indicated on the dial thermometer) should be up to 88°C (190° F). Fan drive engagement should have started to occur at between 74° to 82° C (165° to 180° F). Engagement is distinguishable by a definite increase in fan flow noise (roaring). The timing light also will indicate an increase in the speed of the fan. 7. When the air temperature reaches 88° C (190° F), remove the plastic sheet. Fan drive disengagement should have started to occur at between 57° to 79° C (135° to 175° F). A definite decrease of fan flow noise (roaring) should be noticed. If not, replace the defective viscous fan drive unit. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Page 1661 Fan Clutch: Service and Repair REMOVAL For additional information, also refer to Fan Clutch. 1. Disconnect battery negative cable. Fan Blade/Viscous Fan Drive-3.9L/5.2L/5.9L Engines 2. The thermal viscous fan drive/fan blade assembly is attached (threaded) to water pump hub shaft. Remove fan blade/viscous fan drive assembly from water pump by turning mounting nut counterclockwise as viewed from front. Threads on viscous fan drive are RIGHT HAND. A Snap-On 36 MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP) can be used. Place a bar or screwdriver between water pump pulley bolts to prevent pulley from rotating. 3. Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time. 4. Do not unbolt fan blade assembly from viscous fan drive at this time. 5. Remove fan shroud attaching hardware (two bolts at bottom-two clips at top). 6. Remove fan shroud and fan blade/viscous fan drive assembly as a complete unit from vehicle. 7. After removing fan blade/viscous fan drive assembly, do not place viscous fan drive in horizontal position. If stored horizontally, silicone fluid in the viscous fan drive could drain into its bearing assembly and contaminate lubricant. CAUTION: Do not remove water pump pulley-to-water pump bolts. This pulley is under spring tension. 8. Remove four bolts securing fan blade assembly to viscous fan drive. INSTALLATION 1. Install fan blade assembly to viscous fan drive. Tighten bolts to 23 Nm (17 ft. lbs.) torque. 2. Position fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit. 3. Install fan shroud. 4. Install fan blade/viscous fan drive assembly to water pump shaft and tighten bolts to 27 Nm (20 ft. lbs.). 5. Connect battery negative cable. Viscous Fan Drive Fluid Pump Out Requirement: After installing a new viscous fan drive, bring the engine speed up to approximately 2000 rpm and hold for approximately two minutes. This will ensure proper fluid distribution within the drive. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 11 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1666 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor-Typical Intake Air Temperature Sensor, Engine Coolant Temperature Sensor Connector, Ignition Coil The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1667 Engine Coolant Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1668 Coolant Temperature Sensor/Switch (For Computer): Service Precautions WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1669 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT The engine coolant temperature sensor is installed into a water jacket at the front of the intake manifold located near the rear of the generator. The sensor provides an input voltage to the Powertrain Control Module (PCM) relating coolant temperature. The PCM uses this input along with inputs from other sensors to determine injector pulse width and ignition timing. As coolant temperature varies, the coolant temperature sensor resistance will change. This change in resistance results in a different input voltage to the PCM. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1670 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: Engine Coolant Temperature Sensor-Typical 1. Disconnect wire harness connector from coolant temperature sensor. 2. Engines with air conditioning: When removing the connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place the hook part of tool under the connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. Sensor Resistance(Ohms)-Coolant Temperature Sensor/Intake Air Temperature Sensor 3. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. The resistance (as measured across the sensor terminals) should be as shown in the SENSOR RESISTANCE (OHMS)-COOLANT TEMPERATURE SENSOR/INTAKE AIR TEMPERATURE SENSOR resistance chart. Replace the sensor if it is not within the range of resistance specified in the chart. 4. Test continuity of the wire harness between the PCM wire harness connector and the coolant sensor connector terminals. Refer to Wiring for terminal/cavity locations. Repair the wire harness if an open circuit is indicated. 5. After tests are completed, connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1671 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor-Typical The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain cooling system. 2. Disconnect electrical connector from sensor. 3. Engines with air conditioning: When removing the connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place the hook part of tool under the connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Use long needle nose pliers to connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. 4. Replace any lost engine coolant. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Technical Service Bulletins > Customer Interest for Fan Shroud: > 07-03-99 > Nov > 99 > Engine - Overheats In High Ambient Temperatures. Technical Service Bulletin # 07-03-99 Date: 991105 Engine - Overheats In High Ambient Temperatures. NUMBER: 07-03-99 GROUP: Cooling DATE: Nov. 5, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-98, DATED NOV. 27, 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 CHANGES TO PART NUMBERS, CHANGES TO THE PROCEDURE, AND CHANGES TO THE TIME ALLOTTED TO PERFORM THE REPAIR. SUBJECT: Engine Overheats In High Ambient Temperatures OVERVIEW: This bulletin involves installing a revised fan, fan drive, and fan shroud. MODELS: 1998 - 1999 (DN) Durango SYMPTOM/CONDITION: Some Durangos may experience a high engine temperature condition (temperatures greater than 116°C. (240°F.)) when the vehicle is operated in stop-and-go traffic with ambient temperatures exceeding 32°C (90°F). The result from the high engine temperature may cause the following: ^ Engine Temperature Gauge To Read Higher Than Normal ^ Check Gauge Lamp To Illuminate ^ Warning Chime To Sound ^ Vehicles Equipped With Air Conditioning May Have The A/C System Disabled NOTE: THE POWERTRAIN CONTROL MODULE (PCM) IS DESIGNED TO DISABLE THE AIR CONDITIONING SYSTEM WHEN ENGINE TEMPERATURES EXCEED A PREDETERMINED VALUE AND/OR THE A/C HIGH SIDE PRESSURE EXCEEDS 470 P.S.I. +/- 20 P.S.I.. THIS IS A NORMAL CONDITION DESIGNED TO PROTECT THE ENGINE FROM OVERHEATING AND FROM DAMAGING THE AIC COMPRESSOR. ONCE THE ENGINE TEMPERATURE AND/OR A/C HIGH SIDE PRESSURE HAS LOWERED, THE PCM WILL TURN THE AIR CONDITIONING SYSTEM ON. DIAGNOSIS: 1. Examine the vehicle's cooling system for proper operation. The DRB III can be used to ensure that the engine temperature does not exceed 99° C (210° F) during normal operating conditions. If the engine temperature exceeds 99° C (210° F) during normal operating conditions, the cooling system must be inspected and repaired. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), pages 7-9 through 7-20 for information regarding Cooling System Diagnosis And Testing. NOTE: THIS BULLETIN ADDRESSES ENGINE OVERHEAT CONDITIONS THAT OCCURS ONLY IN STOP-AND-GO TRAFFIC WITH AMBIENT TEMPERATURES EXCEEDING 32aC (90°F). 2. If the vehicle's cooling system is operating normally and the customer identities that the vehicle exhibited the previously stated SYMPTOM/CONDITION, perform the Repair Procedure. PARTS REQUIRED: 1 52027709 Fan, Cooling 1 52029767AA Drive, Fan AR (1) **52029012AD** Shroud, Fan, Four Wheel Drive AR (1) **52028614AC** Shroud, Fan, Two Wheel Drive POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Technical Service Bulletins > Customer Interest for Fan Shroud: > 07-03-99 > Nov > 99 > Engine - Overheats In High Ambient Temperatures. > Page 1680 Labor Operation No: 07-20-01-94 **0.5 Hrs.** FAILURE CODE: P8 - New Part 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. Disconnect and isolate the battery negative cable. 2. The thermal viscous fan drive/fan blade assembly is attached (threaded) to the water pump hub shaft. Remove the fan blade/viscous fan drive assembly from the water pump by turning the attaching nut counterclockwise as viewed from the front of the vehicle. Threads on the viscous fan drive are RIGHT HANDED. A Snap-on 36 mm fan wrench (Snap-on number SP346 from Cummins Diesel Tool Set (Snap-on number 2017DSP)) can be used. The water pump pulley can be held in place by one of the two following methods based upon whether the water pump pulley is pressed onto the water pump or held in place with four attachment bolts. ^ Pressed-On Water Pump Pulley The water pump pulley can be held in place by using Spanner Wrench (Special Tool 6958) and Adapter Pins (Special Tool 8346). ^ Bolt-On Water Pump Pulley Place a bar or screwdriver between the water pump pulley bolts to prevent the pulley from rotating. 3. Remove the four fan shroud bolts securing the shroud to the radiator. 4. Remove the fan shroud and fan blade/viscous fan drive assembly as a complete unit from the vehicle. 5. Remove the four bolts attaching the fan blade to the viscous fan drive. 6. To allow for adjustment of the **revised** fan shroud, drill the **revised upper fan shroud (see Parts Required section)** attachment holes to 15 mm (0.59 in.). 7. Attach the fan blade p/n 52027709 to the revised viscous fan drive p/n 52029767AA using the four bolts removed from the old assembly. Tighten the bolts to 23 N-m (17 ft. lbs.). 8. Position the fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit. 9. Install the **revised** fan shroud onto the radiator leaving the attachment bolts loose. 10. Install the fan blade/viscous fan drive assembly onto the water pump shaft. Tighten the nut to 27 N.m (20 ft. lbs.). 11. Rotate the fan by hand to ensure no contact between the fan blade and the fan shroud. Adjust the position of the fan shroud so that the clearance between the fan blades and the fan shroud are equal throughout the circumference of the shroud and there is 8 mm (0.30 in.) of clearance between the fan blades and the fan shroud. The fan shroud attachment holes can be enlarged even further if necessary to achieve proper clearance as long as the fan shroud bolts continue to have an adequate clamping surface. Tighten the fan shroud bolts. 12. Connect the battery negative cable and reset the clock. 13. Start the engine. Firmly apply the service brakes and put the transmission into "D". Perform a "brake torque" check to ensure that the engine motion does not cause the fan blades to come in contact with the fan shroud. 14. Perform the same test but with the transmission in "R". 15. If the fan blades came in contact with the fan shroud at any time during the previous two tests, readjust the fan shroud as necessary. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fan Shroud: > 07-03-99 > Nov > 99 > Engine - Overheats In High Ambient Temperatures. Technical Service Bulletin # 07-03-99 Date: 991105 Engine - Overheats In High Ambient Temperatures. NUMBER: 07-03-99 GROUP: Cooling DATE: Nov. 5, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-98, DATED NOV. 27, 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 CHANGES TO PART NUMBERS, CHANGES TO THE PROCEDURE, AND CHANGES TO THE TIME ALLOTTED TO PERFORM THE REPAIR. SUBJECT: Engine Overheats In High Ambient Temperatures OVERVIEW: This bulletin involves installing a revised fan, fan drive, and fan shroud. MODELS: 1998 - 1999 (DN) Durango SYMPTOM/CONDITION: Some Durangos may experience a high engine temperature condition (temperatures greater than 116°C. (240°F.)) when the vehicle is operated in stop-and-go traffic with ambient temperatures exceeding 32°C (90°F). The result from the high engine temperature may cause the following: ^ Engine Temperature Gauge To Read Higher Than Normal ^ Check Gauge Lamp To Illuminate ^ Warning Chime To Sound ^ Vehicles Equipped With Air Conditioning May Have The A/C System Disabled NOTE: THE POWERTRAIN CONTROL MODULE (PCM) IS DESIGNED TO DISABLE THE AIR CONDITIONING SYSTEM WHEN ENGINE TEMPERATURES EXCEED A PREDETERMINED VALUE AND/OR THE A/C HIGH SIDE PRESSURE EXCEEDS 470 P.S.I. +/- 20 P.S.I.. THIS IS A NORMAL CONDITION DESIGNED TO PROTECT THE ENGINE FROM OVERHEATING AND FROM DAMAGING THE AIC COMPRESSOR. ONCE THE ENGINE TEMPERATURE AND/OR A/C HIGH SIDE PRESSURE HAS LOWERED, THE PCM WILL TURN THE AIR CONDITIONING SYSTEM ON. DIAGNOSIS: 1. Examine the vehicle's cooling system for proper operation. The DRB III can be used to ensure that the engine temperature does not exceed 99° C (210° F) during normal operating conditions. If the engine temperature exceeds 99° C (210° F) during normal operating conditions, the cooling system must be inspected and repaired. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), pages 7-9 through 7-20 for information regarding Cooling System Diagnosis And Testing. NOTE: THIS BULLETIN ADDRESSES ENGINE OVERHEAT CONDITIONS THAT OCCURS ONLY IN STOP-AND-GO TRAFFIC WITH AMBIENT TEMPERATURES EXCEEDING 32aC (90°F). 2. If the vehicle's cooling system is operating normally and the customer identities that the vehicle exhibited the previously stated SYMPTOM/CONDITION, perform the Repair Procedure. PARTS REQUIRED: 1 52027709 Fan, Cooling 1 52029767AA Drive, Fan AR (1) **52029012AD** Shroud, Fan, Four Wheel Drive AR (1) **52028614AC** Shroud, Fan, Two Wheel Drive POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fan Shroud: > 07-03-99 > Nov > 99 > Engine - Overheats In High Ambient Temperatures. > Page 1686 Labor Operation No: 07-20-01-94 **0.5 Hrs.** FAILURE CODE: P8 - New Part 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. Disconnect and isolate the battery negative cable. 2. The thermal viscous fan drive/fan blade assembly is attached (threaded) to the water pump hub shaft. Remove the fan blade/viscous fan drive assembly from the water pump by turning the attaching nut counterclockwise as viewed from the front of the vehicle. Threads on the viscous fan drive are RIGHT HANDED. A Snap-on 36 mm fan wrench (Snap-on number SP346 from Cummins Diesel Tool Set (Snap-on number 2017DSP)) can be used. The water pump pulley can be held in place by one of the two following methods based upon whether the water pump pulley is pressed onto the water pump or held in place with four attachment bolts. ^ Pressed-On Water Pump Pulley The water pump pulley can be held in place by using Spanner Wrench (Special Tool 6958) and Adapter Pins (Special Tool 8346). ^ Bolt-On Water Pump Pulley Place a bar or screwdriver between the water pump pulley bolts to prevent the pulley from rotating. 3. Remove the four fan shroud bolts securing the shroud to the radiator. 4. Remove the fan shroud and fan blade/viscous fan drive assembly as a complete unit from the vehicle. 5. Remove the four bolts attaching the fan blade to the viscous fan drive. 6. To allow for adjustment of the **revised** fan shroud, drill the **revised upper fan shroud (see Parts Required section)** attachment holes to 15 mm (0.59 in.). 7. Attach the fan blade p/n 52027709 to the revised viscous fan drive p/n 52029767AA using the four bolts removed from the old assembly. Tighten the bolts to 23 N-m (17 ft. lbs.). 8. Position the fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit. 9. Install the **revised** fan shroud onto the radiator leaving the attachment bolts loose. 10. Install the fan blade/viscous fan drive assembly onto the water pump shaft. Tighten the nut to 27 N.m (20 ft. lbs.). 11. Rotate the fan by hand to ensure no contact between the fan blade and the fan shroud. Adjust the position of the fan shroud so that the clearance between the fan blades and the fan shroud are equal throughout the circumference of the shroud and there is 8 mm (0.30 in.) of clearance between the fan blades and the fan shroud. The fan shroud attachment holes can be enlarged even further if necessary to achieve proper clearance as long as the fan shroud bolts continue to have an adequate clamping surface. Tighten the fan shroud bolts. 12. Connect the battery negative cable and reset the clock. 13. Start the engine. Firmly apply the service brakes and put the transmission into "D". Perform a "brake torque" check to ensure that the engine motion does not cause the fan blades to come in contact with the fan shroud. 14. Perform the same test but with the transmission in "R". 15. If the fan blades came in contact with the fan shroud at any time during the previous two tests, readjust the fan shroud as necessary. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Technical Service Bulletins > Page 1687 Fan Shroud: Specifications Fan Shroud Bolts 50 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations Heater Core: Locations The heater core is located in the heater-A/C housing, under the instrument panel. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations > Page 1691 Heater Core: Description and Operation SYSTEM DESCRIPTION It is a heat exchanger made of rows of tubes and fins. 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 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations > Page 1692 Heater Core: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. 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, Heater - A/C Housing Removal and Installation, See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Heater - A/C Housing Removal and Installation Heater Core Remove/Install 2. 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 and reinstall the heater-A/C housing in the vehicle. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Heater - A/C Housing Removal and Installation, See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Heater - A/C Housing Removal and Installation Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. bulb Application Temperature Indicator Lamp ............................................................................................................... .............................................................. PC194 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair Radiator Drain Plug: Service and Repair REMOVAL WARNING: DO NOT LOOSEN RADIATOR DRAINCOCK WITH SYSTEM HOT AND PRESSURIZED. SERIOUS BURNS FROM COOLANT CAN OCCUR. Draincock Assembly 1. Unscrew draincock stem (counterclockwise rotation). When stem is completely unscrewed, pull it from radiator tank and draincock body. Draincock Body Removal 2. Using a pair of needle nose pliers, compress draincock body and pull straight out of radiator. INSTALLATION Draincock Assembled For Installation 1. Install draincock stem loosely into body. The draincock assembly cannot be installed if stem is threaded into the body. 2. Push draincock assembly into opening in radiator tank. It will snap into place when fully seated. 3. Tighten draincock (clockwise) to 2.0 to 2.7 Nm (18 - 25 inch lbs.) torque. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation Radiator Cap: Description and Operation Radiators are equipped with a pressure cap, which releases pressure at some point within a range of 97 - 124 kPa (14 - 18 psi). The pressure relief point (in pounds) is engraved on top of cap. Radiator Pressure Cap And Filler Neck 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 that opens when system pressure reaches release range of 97 124 kPa (14 - 18 psi). A vent valve in the center of cap allows a small coolant flow through cap when coolant is below boiling temperature. The valve is completely closed when boiling point is reached. As the coolant cools, it contracts and creates a vacuum in the cooling system. This causes the vacuum valve to open and coolant in the reserve/overflow tank to be drawn through its connecting hose into radiator. If the vacuum valve is stuck shut, the radiator hoses will collapse on cooldown. Clean the vent valve. A rubber gasket seals radiator filler neck to prevent leakage. This is done to keep system under pressure. It also maintains vacuum during coolant cool-down allowing coolant to return from reserve/ overflow tank. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation > Page 1704 Radiator Cap: Testing and Inspection RADIATOR CAP-TO-FILLER NECK SEAL PRESSURE RELIEF CHECK 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 69-124 kPa (10-18 psi) and hold pressure at a minimum of 55 kPa (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. RADIATOR CAP-PRESSURE TESTING Pressure Testing Radiator Cap-Typical 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 104 kPa (15 psi) on gauge. If pressure cap fails to hold pressure of at least 97 kPa (14 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. CLEANING AND INSPECTION Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation > Page 1705 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 11 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1711 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor-Typical Intake Air Temperature Sensor, Engine Coolant Temperature Sensor Connector, Ignition Coil The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1712 Engine Coolant Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1713 Coolant Temperature Sensor/Switch (For Computer): Service Precautions WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1714 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT The engine coolant temperature sensor is installed into a water jacket at the front of the intake manifold located near the rear of the generator. The sensor provides an input voltage to the Powertrain Control Module (PCM) relating coolant temperature. The PCM uses this input along with inputs from other sensors to determine injector pulse width and ignition timing. As coolant temperature varies, the coolant temperature sensor resistance will change. This change in resistance results in a different input voltage to the PCM. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1715 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: Engine Coolant Temperature Sensor-Typical 1. Disconnect wire harness connector from coolant temperature sensor. 2. Engines with air conditioning: When removing the connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place the hook part of tool under the connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. Sensor Resistance(Ohms)-Coolant Temperature Sensor/Intake Air Temperature Sensor 3. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. The resistance (as measured across the sensor terminals) should be as shown in the SENSOR RESISTANCE (OHMS)-COOLANT TEMPERATURE SENSOR/INTAKE AIR TEMPERATURE SENSOR resistance chart. Replace the sensor if it is not within the range of resistance specified in the chart. 4. Test continuity of the wire harness between the PCM wire harness connector and the coolant sensor connector terminals. Refer to Wiring for terminal/cavity locations. Repair the wire harness if an open circuit is indicated. 5. After tests are completed, connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1716 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor-Typical The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain cooling system. 2. Disconnect electrical connector from sensor. 3. Engines with air conditioning: When removing the connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place the hook part of tool under the connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Use long needle nose pliers to connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. 4. Replace any lost engine coolant. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. bulb Application Temperature Indicator Lamp ............................................................................................................... .............................................................. PC194 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications THERMOSTAT TEMPERATURE OPERATING RANGE: INFORMATION NOT SUPPLIED BY THE MANUFACTURER. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1723 Thermostat: Description and Operation Thermostat-3.9L/5.2L/5.9L Engines On 3.9L and 5.21J5.9L engines, the thermostat is located beneath the thermostat housing at front of intake manifold. This thermostat has an air bleed notch. Thermostats installed in the 3.9TJ5.2I-J5.9L engines are of the wax- pellet-driven, reverse-poppetchoke-type. The wax pellet is located in a sealed container at spring end of thermostat. When heated, the pellet expands, overcoming closing spring tension and water pump pressure to force valve to open. Coolant leakage into pellet container will cause thermostat to fail in open position. Do not attempt to free a sticking thermostat with a prying device. The thermostat controls the operating temperature of the engine by controlling the amount of coolant flow to radiator. On all engines, the thermostat is closed below 88°C (192°F). When coolant reaches this temperature, thermostat begins to open allowing coolant flow to radiator. This provides quick engine warm-up and overall temperature control. The thermostat is designed to provide a minimum engine operating temperature range of from 88 to 93° C (192 to 199°F). The thermostat should be fully open for maximum coolant flow during operation in hot ambient temperatures of approximately 104°C (220°F). Above 104°C (220°F), coolant temperature is controlled by radiator, fan and ambient temperature. An arrow, plus the word UP is stamped on front flange next to air bleed. The words TO RAD are stamped on one arm of thermostat. They indicate proper installed position. The same thermostat is used for winter and summer seasons. CAUTION: Do not operate an engine without a thermostat, except for servicing or testing. An engine should not be operated without a thermostat, except for servicing or testing. Operating without a thermostat causes longer engine warm-up time, unreliable warm-up performance, increased exhaust emissions and crankcase condensation that can result in sludge formation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1724 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) in Powertrain Management 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 Cooling System Diagnosis and Testing. For other DTC numbers, refer to On-Board Diagnostics in Powertrain Management. The DTC can also be accessed through the DRB scan tool. Refer to Powertrain Management for diagnostic information and operation of the DRB scan tool. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1725 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. Factory installed thermostat housings on 3.9L/ 5.2L/5.9L engines are installed on a gasket with an anti-stick coating. This will aid in gasket removal and clean-up. 1. Disconnect negative battery cable at battery. 2. Drain cooling system until coolant level is below thermostat. Generator-A/C Compressor Mounting Bracket-3.9L/5.2L/5.9L Engine 3. Air Conditioned vehicles: Remove support bracket (generator mounting bracket-to-intake manifold) located near rear of generator. 4. On air conditioning equipped vehicles, the generator must be partially removed. Automatic Belt Tensioner Assembly Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1726 a. Remove generator drive belt as follows: Drive belts on both 3.9L and 5.2L/5.9L engines are equipped with a spring loaded automatic belt tensioner. b. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. c. Rotate tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. d. Remove belt from vehicle. e. Remove two generator mounting bolts. Do not remove any wiring at generator. If equipped with 4WD, unplug 4WD indicator lamp wiring harness (located near rear of generator). f. Remove generator. Position generator to gain access for thermostat gasket removal. 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. 5. Remove upper radiator hose clamp and upper radiator hose at thermostat housing. 6. Position wiring harness (behind thermostat housing) to gain access to thermostat housing. 7. Remove thermostat housing mounting bolts, thermostat housing, gasket and thermostat. Discard old gasket. INSTALLATION 1. Clean mating areas of intake manifold and thermostat housing. 2. Install thermostat (spring side down) into recessed machined groove on intake manifold. 3. Install gasket on intake manifold and over thermostat. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1727 Thermostat Position-3.9L/5.2L/5.9L Engines 4. Position thermostat housing to intake manifold. Note the word FRONT stamped on housing. For adequate clearance, this must be placed towards front of vehicle. The housing is slightly angled forward after installation to intake manifold. 5. Install two housing-to-intake manifold bolts. Tighten bolts to 23 Nm (200 inch lbs.) torque. 6. Install upper radiator hose to thermostat housing. 7. Air Conditioned vehicles: Belt Routing-3.9L/5.2L/5.9L Engines CAUTION: When installing the serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. For correct 3.9/5.2L engine belt routing. The correct belt with correct length must be used. a. Install generator. Tighten bolts to 41 Nm (30 ft. lbs.). b. Install support bracket (generator mounting bracket-to-intake manifold). Tighten bolts to 54 Nm (40 ft. lbs.) torque. c. Position drive belt over all pulleys except idler pulley (located between generator and A/C compressor). d. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. e. Rotate socket/wrench clockwise. Place belt over idler pulley. Let tensioner rotate back into place. Remove wrench. Be sure belt is properly seated on all pulleys. 8. Fill cooling system. 9. Connect battery negative cable. 10. Start and warm the engine. Check for leaks. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Thermostat Housing Bolts 15 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Mounting Bolts 30 ft.lb Water Pump Pulley 16 ft.lb Water Pump-to-Chain Case Cover Bolt 31 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1734 Water Pump: Description and Operation Reverse Rotating Water Pump-Typical 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 drive belt. The water pump impeller is pressed onto the rear of a shaft that rotates in a bearing pressed into the water pump body. The body has a small hole for ventilation. The water pump seals are lubricated by antifreeze in the coolant mixture. Additional lubrication is not necessary. A quick test to determine if pump is working is to check if heater warms properly. A defective water pump will not be able to circulate heated coolant through the long heater hose to the heater core, The water pump is bolted directly to the engine timing case/cover. A gasket is used as a seal between the water pump and timing chain case/cover. The water pump on all models can be removed without discharging the air conditioning system (if equipped). If water pump is replaced because of bearing/shaft damage, or leaking shaft seal, the mechanical cooling fan assembly should also be inspected. Inspect for fatigue cracks, loose blades, or loose rivets that could have resulted from excessive vibration. Replace fan if any of these conditions are found. Also check condition of the thermal Viscous Fan Drive. Refer to Fan Clutch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1735 Water Pump: Testing and Inspection Replace water pump assembly if it has any of the following conditions: ^ The body is cracked or damaged ^ Water leaks from shaft seal. This is evident by traces of coolant below vent hole ^ Loose or rough turning bearing. Also inspect viscous fan drive ^ Impeller rubs either the pump body or timing chain case/cover Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1736 Water Pump: Service and Repair REMOVAL The water pump can be removed and installed without discharging the air conditioning system (if equipped). 1. Disconnect battery negative cable. 2. Drain cooling system. 3. 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. 4. Remove upper radiator hose clamp and hose at radiator. Fan Blade And Viscous Fan Drive-3.9L/5.2L/5.9L Engines 5. The thermal viscous fan drive is attached (threaded) to the water pump hub shaft. Remove fan/viscous fan drive assembly from water pump by turning mounting nut counterclockwise as viewed from front. Threads on viscous fan drive are RIGHT HAND. A Snap-On 36 MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP) can be used. Place a bar or screwdriver between water pump pulley bolts to prevent pulley from rotating. Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time. 6. If water pump is being replaced, do not unbolt fan blade assembly from thermal viscous fan drive. 7. Remove fan shroud attaching hardware (two bolts at bottom-two clips at top). 8. Remove fan shroud and fan blade/viscous fan drive assembly from vehicle as a complete unit. 9. 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. 10. Do not remove water pump pulley bolts at this time. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1737 Automatic Belt Tensioner Assembly-3.9L/5.2L/5.9L Engines 11. Remove accessory drive belt as follows: The drive belt is equipped with a spring loaded automatic tensioner. Relax tension from belt by rotating tensioner clockwise (as viewed from front). When all belt tension has been relaxed, remove accessory drive belt. 12. Remove four water pump pulley-to-water pump hub bolts and remove pulley from vehicle. 13. Remove lower radiator hose clamp and remove lower hose at water pump. 14. Remove heater hose clamp and heater hose from heater hose coolant return tube. Coolant Return Tube-3.9L/5.2L/5.9L Engines-Typical 15. Loosen heater hose coolant return tube mounting bolt and remove tube from water pump. Discard the old tube O-ring. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1738 Water Pump Bolts-3.9L/5.2L/5.9L Engines 16. Remove seven water pump mounting bolts. 17. Loosen clamp at water pump end of bypass hose. Slip bypass hose from water pump while removing pump from vehicle. Discard old gasket. CAUTION: Do not pry water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks. INSTALLATION 1. Clean gasket mating surfaces. 2. Using a new gasket, install water pump to engine as follows: Guide water pump nipple into bypass hose as pump is being installed. Install water pump bolts. Tighten water pump mounting bolts to 40 Nm (30 ft. lbs.) torque. 3. Position bypass hose clamp to bypass hose. 4. Spin water pump to be sure that pump impeller does not rub against timing chain case/cover. 5. Install a new O-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. Be sure the slot in tube bracket is bottomed to mounting bolt. This will properly position return tube. 7. Connect radiator lower hose to water pump. 8. Connect heater hose and hose clamp to coolant return tube. 9. Install water pump pulley. Tighten bolts to 27 Nm (20 ft. lbs.) torque. Place a bar or screwdriver between water pump pulley bolts to prevent pulley from rotating. 10. Relax tension from belt tensioner. Install accessory drive belt. Belt Routing-3.9L/5.2L/5.9L Engines CAUTION: When installing the serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. For correct belt routing. The correct belt with correct length must be used. 11. Position fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1739 12. Install fan shroud. 13. Install fan blade/viscous fan drive assembly to water pump shaft. 14. Fill cooling system. 15. Connect battery negative cable. 16. Start and warm the engine. Check for leaks. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation The stainless steel catalytic converter body is designed to last the life of the vehicle. Excessive heat can result in bulging or other distortion, but excessive heat will not be the fault of the converter. If unburned fuel enters the converter, overheating may occur. If a converter is heat-damaged, correct the cause of the damage at the same time the converter is replaced. Also, inspect all other components of the exhaust system for heat damage. Unleaded gasoline must be used to avoid contaminating the catalyst core. DO NOT remove spark plug wires from plugs or by any other means short out cylinders. Failure of the catalytic converter can occur due to a temperature increase caused by unburned fuel passing through the converter. DO NOT allow the engine to operate at fast idle for extended periods (over 5 minutes). This condition may result in excessive temperatures in the exhaust system and on the floor pan. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 1744 Catalytic Converter: Service and Repair 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. REMOVAL 1. Disconnect battery negative cable. 2. Remove passenger front seat track left rear mounting bolt (4X4 vehicles only). 3. Raise vehicle on hoist. 4. Remove tailpipe from rear hanger isolators. 5. Remove muffler to catalytic converter exhaust clamp. 6. Heat connection with an oxygen/acetylene torch and separate muffler from catalytic converter. 7. Disconnect catalytic converter rear hanger from isolators. 8. Disconnect downstream oxygen sensor. Catalytic Converter Removal/Installation 9. Remove catalytic converter to exhaust pipe clamp. 10. Heat connection with oxygen/acetylene and separate muffler from catalytic converter. 11. If equipped, remove front axle propeller shaft. Refer to Transmission and Drivetrain, Transfer Case for the correct procedure. 12. Disconnect upstream oxygen sensor. 13. Remove upper exhaust pipe to manifold bolts (one from each side) and allow exhaust pipe to hang. 14. Support transmission/transfer case with a stand and remove the transmission mount to crossmember nuts. 15. Remove transmission crossmember to frame bolts and move crossmember as far rearward (towards torsion bar crossmember) as possible. 16. Remove catalytic converter rear hanger. 17. Slide converter forward and out of vehicle. INSTALLATION 1. If the converter is being replaced, transfer oxygen sensor from old converter and tighten to 30 Nm (22 inch lbs.). 2. Install catalytic converter into place. 3. Slide transmission crossmember into place and tighten crossmember mounting bolts to 47 Nm (35 ft. lbs.). 4. Lower transmission/transfer case into place and remove stand. 5. Install and tighten transmission mount nuts to 47 Nm (35 ft. lbs.). 6. Install the converter hanger bracket and tighten bolts to 23 Nm (200 inch lbs.). 7. Install the two exhaust pipe to manifold bolts and tighten by hand. 8. Install catalytic converter to exhaust pipe with a new exhaust clamp. Start nuts by hand. 9. Install catalytic converter into hanger isolators. 10. Install muffler onto catalytic converter with a new clamp. Tighten nuts by hand. 11. If equipped, install front axle propeller shaft 12. Install muffler into rear hanger isolators. 13. Install tailpipe hanger into isolator. 14. Inspect exhaust system for contact with body or drivetrain components. Align as necessary. 15. Tighten exhaust pipe to manifold bolts to 34 Nm (25 ft. lbs.). 16. Tighten converter to exhaust pipe clamp to 43 Nm (32 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 1745 17. Tighten muffler to converter clamp to 43 Nm (32 ft. lbs.). 18. Lower vehicle. 19. Install passenger front seat track left rear mounting bolt (4X4 vehicles only). 20. Connect battery negative cable. 21. Start engine and check for exhaust leaks. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications To Head Bolts/Nuts ............................................................................................................................. ..................................................... 34 Nm (25 ft. lbs.) To Exhaust Pipe ............................................... ......................................................................................................................................... 26 Nm (19 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1749 Exhaust Manifold: Description and Operation The exhaust manifolds are constructed of cast iron and are LOG type with balanced flow. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1. Disconnect the battery negative cable. 2. Raise vehicle on hoist. 3. Remove the exhaust pipe to manifold nuts. 4. Lower the vehicle. Exhaust Manifold Heat Shield(s)-5.9L Engine 5. Remove the manifold heat shield nuts, shield, washers and extensions. 6. Disconnect the EGR tube from the right side manifold. Remove bolts, nuts and washers attaching manifold to cylinder head. 7. Remove manifold from the cylinder head. INSTALLATION CAUTION: If the studs came out with the nuts when removing the exhaust manifold, install new studs. Exhaust Manifold Installation-5.9L Engine 1. Position the exhaust manifolds on the two studs located on the cylinder head. Install conical washers and nuts on these studs. 2. Install new bolt and washer assemblies in the remaining holes. Start at the center arm and work outward. Tighten the bolts and nuts to 24 Nm (18 ft. lbs.) torque. 3. Install the manifold heat shield extensions and torque to 24 Nm (210 inch lbs.) 4. Install the washers, shields, and nuts and torque the nuts to 14 Nm (120 inch lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 1752 5. Raise the vehicle. 6. Assemble the exhaust pipe to the exhaust manifold and secure with bolts, nuts and washers. Tighten these nuts to 27 Nm (20 ft. lbs.) torque. 7. Lower the vehicle. 8. Connect the battery negative cable. 9. Start vehicle and inspect for exhaust leaks. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 1753 Exhaust Manifold: Service and Repair Cleaning and Inspection CLEANING Clean mating surfaces on cylinder head and manifold, wash with solvent and blow dry with compressed air. Inspect manifold for cracks. INSPECTION Inspect mating surfaces of manifold for flatness with a straight edge. Seal surfaces must be flat within 0.1 mm. (0.004 inch) overall. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications Exhaust Pipe: Specifications Exhaust Pipe to Manifold Nuts 25 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe Replacement Exhaust Pipe: Service and Repair Exhaust Pipe Replacement 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. REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. If equipped, remove front driveshaft assembly. (Refer to Transmission and Drivetrain, Transfer Case for the correct procedures). 4. Disconnect upstream oxygen sensor. Exhaust Pipe Removal/Installation 5. Remove exhaust pipe to manifold nuts. 6. Remove exhaust pipe to catalytic converter clamp. 7. Heat exhaust pipe to converter connection with an oxygen/acetylene torch and twist converter out of exhaust pipe. 8. Remove exhaust pipe. 9. If replacing exhaust pipe, remove upstream oxygen sensor and transfer to new pipe. INSTALLATION 1. Install exhaust pipe and start the pipe to manifold nuts by hand. (DO NOT TIGHTEN). 2. Connect exhaust pipe to catalytic converter and install exhaust clamp. Start nuts by hand. 3. Align exhaust pipe and tighten exhaust pipe to manifold nuts to 34 Nm (25 ft. lbs.). 4. Tighten exhaust pipe to catalytic converter clamp nuts to 43 Nm (32 ft. lbs.). 5. If removed, install oxygen sensor and tighten to 30 Nm (22 ft. lbs.). 6. Connect oxygen sensor connector. 7. If equipped, install front driveshaft. 8. Lower vehicle and connect battery negative cable. 9. Start engine and inspect for exhaust leaks. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe Replacement > Page 1759 Exhaust Pipe: Service and Repair Tailpipe Replacement 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. REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. Tailpipe Removal/Installation 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 43 Nm (32 ft. lbs.). 4. Lower vehicle and connect battery negative cable. 5. Start engine and check for exhaust leaks. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Specifications Exhaust Pipe/Muffler Hanger: Specifications Muffler Hanger Bolts 200 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications Heat Shield: Specifications Heat Shield (to body) Nuts 60 in.lb Heat Shield (mainfolds) Screws 120 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1766 Heat Shield: Description and Operation Heat shields are needed to protect both the vehicle and the environment from the high temperatures developed by the catalytic converter. The catalytic converter releases additional heat into the exhaust system. Under severe operating conditions, the temperature increases in the area of the converter. Such conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. CAUTION: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shields. Light overspray near the edges is permitted. Application of coating will result in excessive floor pan temperatures and objectionable fumes. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1767 Heat Shield: Service and Repair REMOVAL 1. Raise and support the vehicle. Front And Rear Floor Pan/converter Shields Rear Compartment/Tailpipe Heat Shield Left And Right Dash Heat Shield Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1768 Muffler Heat Shield 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair 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. REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. Muffler Removal/Installation 3. Remove muffler to 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 catalytic converter connection and twist muffler off of converter pipe. INSTALLATION 1. Install muffler to 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 43 Nm (32 ft. lbs.). 5. Lower vehicle and connect battery negative cable. 6. Start engine and check for exhaust leaks. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Locations Central Timer Module: Locations Module Locations CENTRAL TIMER MODULE The Durango utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The Base CTM does not communicate on the CCD bus and will not be addressed. The CTM performs most of the typical functions a Body Control Module would perform. The module is located on the right side of the glove box behind a metal bracket. It contains a white 18-way and a green 14-way connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN WHILE IN MOTION. DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1780 Central Timer Module: 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module Central Timer Module: Description and Operation Central Timer Module DESCRIPTION Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the highline models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD 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. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. For diagnosis of the base version of the CTM, refer to Central Timer Module in the Diagnosis and Testing - Chime/Buzzer Warning Systems. For diagnosis of the high-line version of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-afterwash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermittent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. Refer to Central Timer module/Service and Repair of Instrument Panel Systems for the service procedures. See Wiper System Diagnosis and Testing for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. 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 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 Chrysler Collision Detection (CCD) 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. Refer to Remote Radio Switch in the Description and Operation for more information on this component. In addition, radio receivers connected to the CCD 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. The high-line CTM controls features and functions of the power lock, illuminated entry, and Remote Keyless Entry (RKE) systems. The high-line CTM receives hard wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio frequency inputs from the RKE transmitters. In response to those and many other inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the headlamp and horn relays, and the courtesy lamps. Some of the features and functions of the power lock, illuminated entry and RKE systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch when the driver door is open if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually, with a key, or energized with the RKE transmitter. - A programmable driver door unlock feature. The driver door unlock feature allows one press of the RKE transmitter Unlock button to unlock Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 1783 just the driver door, and a second press within five seconds to unlock all doors and the liftgate. If disabled, one press of the RKE transmitter Unlock button willunlock all doors and the liftgate. - A panic mode feature which can provide additional personal security and protection. When the Panic button on the RKE transmitter is depressed the vehicle horn will pulse, the headlights will flash, and the interior lights will illuminate on the vehicle for about three minutes, or until the Panic button is depressed a second time. A vehicle speed of about 24 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. - An enhanced accident response feature will unlock all doors and the liftgate, then prevent thepower door lock system from locking the doors and liftgate for a predetermined time interval, after receiving a CCD message from the ACM indicating a frontal impact of the vehicle requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates that the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors and the liftgate after the vehicle reaches a speed of about 24 kilometers-per-hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again, at any speed above 24 kilometers-per-hour (15 miles-per-hour). - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following activation of the RKE Lock function. This feature can be enabled or disabled and, if enabled, the horn chirp duration (twenty or forty milliseconds) can be selected. - Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the service procedures. - The programmable features of the CTM can be enabled or disabled using the DRB scan tool as described in the proper Diagnostic Procedures. These features can also be enabled/disabled using the customer programmable feature. See the owner's manual in the vehicle glove box for more information on the customer programmable feature. Refer to Central Timer Module in the Diagnosis and Testing for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. - One of the features that the high-line CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard- wired inputs from the door and liftgate ajar, door and liftgate lock cylinder, and ignition switches. The programming in the CTM allows it to process the information from these inputs and send control outputs to energize or de-energize the headlamp (or security) relay, horn relay, and the security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS - The high-line CTM also contains the receiver and control logic for the power lock and Remote Keyless Entry (RKE) systems, which are integrated into the arming, disarming, and triggering functions of the VTSS. - Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the service procedures. - For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. - One of the functions and features that both versions of the CTM support is the chime warning system. The CTM contains a chime tone generator to perform the functions of the chime warning module. The CTM uses hard-wired switch inputs, internal programming, and a hard-wired chime request input from the instrument cluster circuitry to detect when a chime tone is required. This covers the diagnosis and service of only the hard-wired inputs used by the CTM to determine that a chime tone should be generated. See Central Timer Module Diagnosis and Testing for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. OPERATION Some of the functions and features that the CTM supports or controls include: Chimes for the following conditions: - Headlamps on with ignition off and driver door open warning - Key in ignition with ignition off and driver door open warning - ABS lamp warning (if the vehicle is so equipped) - Airbag lamp warning - Check gauges lamp warning - Door ajar lamp warning - Low fuel lamp warning - Low washer fluid lamp warning - Seat belt reminder lamp warning Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 1784 - Transmission oil temperature lamp warning (automatic transmission) - Courtesy lamp defeat - Courtesy lamp time-out (high-line only) - Intermittent wipe control - Enhanced accident response (high-line only) - Horn chirp upon door lock with RKE (customer programmable) (high-line only) - Illuminated entry (high-line only) - Power door lock control (high-line only) - Power lock inhibit (high-line only) - Remote Keyless Entry (RKE) (high-line only) - Remote radio switches (high-line only) - Rolling door locks (customer programmable) (high-line only) - Speed sensitive intermittent wipe (high-line only) - Vehicle Theft Security System (VTSS) (high-line only) (if the vehicle is so equipped) - Wipe after wash (high-line only). More information on the operation of these CTM features and functions can be found in the system to which that feature or function applies. CENTRAL TIMER MODULE The Durango utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The Base CTM does not communicate on the CCD bus and will not be addressed. The CTM performs most of the typical functions a Body Control Module would perform. The Highline CTM provides the following features: Remote Keyless Entry (RKE) - Chime - Courtesy Lamp controls/Illuminated Entry - Power Door Locks - Speed Sensitive Intermittent Wipers - Enhanced Accident Response - Vehicle Theft Security System (VTSS) The module is located on the right side of the glove box behind a metal bracket. It contains a white 18-way and a green 14-way connector. Central Timer Module Diagnostic Trouble Codes - Door Disarm Switch Failure - Door Lock Switch Failure - Door Unlock Switch Failure - Wiper Park Switch Failure - EEPROM Checksum Failure - Internal ROM Test Failure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 1785 Central Timer Module: Description and Operation DRB III Error Messages and Blank Screen DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB will display one of only two error messages: User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, recored the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key itf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III Does Not Power Up (blank Screen) 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. Perform the "DRB Blank Screen" test under Vehicle Communication. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Information Bus/DRB Blank Screen DRB III Display Is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 1786 Central Timer Module: Description and Operation General Information Module Locations SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 1999 Durango consists of five modules that communicate over the CCD bus (Chrysler Collision Detection multiplex system). There are two additional modules, the Powertrain Control Module (PCM) and the Controller Anti-Lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication, The CAB also utilizes the bus for diagnostics. The PCM sends and receives messages on the CCD bus, however diagnostics are performed through the Serial Communication Interface (SCI), the same as previous years. All of the information about the functioning of all the systems is organized, controlled, and communicated by the CCD bus, which is described in Vehicle Communication. Through the CCD 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 the information to perform it's 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. 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 CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Mechanical Instrument Cluster (MIC) from the ACM via the CCD 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. Perform the WARNING LAMP CIRCUIT OPEN procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: warning lamp does not illuminate - warning lamp stays illuminated 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 1787 AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. CENTRAL TIMER MODULE The Durango utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The Base CTM does not communicate on the CCD bus and will not be addressed. The CTM performs most of the typical functions a Body Control Module would perform. The Highline CTM provides the following features: Remote Keyless Entry (RKE) - Chime - Courtesy Lamp controls/Illuminated Entry - Power Door Locks - Speed Sensitive Intermittent Wipers - Enhanced Accident Response - Vehicle Theft Security System (VTSS) The module is located on the right side of the glove box behind a metal bracket. It contains a white 18-way and a green 14-way connector. Chime system The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for seat belt, gauge problems and tell-tale warnings. There are two chime rates, Low; 50 ± 12 chimes per minute for reminders and High; 180 ± 12 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 doors are open or the headlights 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 approximately 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 - Seat belt warning - Check engine lamp illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Anti-lock lamp illuminated (after prove-out if equipped) - Check gauges lamp illuminated - Low fuel warning lamp illuminated - Low washer fluid - Door ajar 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/100Km since the last reset. Instantaneous Fuel Economy Shows the fuel economy for the last few seconds in MPG or L/100Km. 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 minitrip computer displays. US/M Button Press this button to convert all vehicle displays from US to Metric to US. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 1788 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, Trip Odometer, ET) is currently being displayed. 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. Enhanced Accident Response (Highline CTM Only) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the CCD bus to the CTM module to unlock the doors. The interior lights will be turned ON when the vehicle speed message on the CCD 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. Interior Lighting The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The highline CTM also provides for illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door disarm switch input or the door jamb switch input, the interior courtesy lights will be turned ON. The illuminated entry function is canceled if the CTM senses an ignition "ON" condition or the "lock" command from a valid key fob. If a door is left open or turned ON by rotation of dimmer switch for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned ON by courtesy lamp switch, the CTM will not be able to turn them OFF. The Durango utilizes an interior light defeat switch as an integral part of the headlamp switch. Mechanical Instrument Cluster (MIC) The MIC is available in 4 different versions. Two of the versions are Canadian clusters. There is a highline and a low line cluster available. The difference is the addition of a tachometer in the highline. In order to accomplish this, the fuel level gauge is reduced in size and oil pressure gauge is relocated. The cluster positions its gauges with bus messages received from the PCM. The odometer is a Liquid Crystal Display (LCD). The cluster will provide bus bias and the PCM provides termination. The MIC has an internal diagnostic routing that can be accessed by pushing and holding the trip odometer while rotating the key to the ON position. The cluster will then place all the gauges at their calibration points and will light all the CCD driven tell-tales. It will also light all the segments of the LCD display for a visual verification check. The MIC can verify communications with the PCM, ID the module, or change the country code by using options 1, 3, or 9 on the DRB III under the MIC menu. If there are faults found during the diagnostic routine, the cluster will report them on the LCD odometer display. Power Door Locks The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is OFF, the door is open, and the key is in the ignition. Automatic or "rolling locks" are included as a DRB III, or customer 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 CCD bus) indicating acceleration, the CTM will cycle the lock actuators to lock the doors. RKE/VTSS If the vehicle is equipped with Remote Keyless Entry (RKE), programming of additional transmitters and horn chirp are customer programmable features, The highline CTM provides for RKE and the Vehicle Theft Security System (VTSS). The base CTM is not able to provide these functions. The presence of either of these options dictates that the vehicle is equipped with a highline CTM. The VTSS system monitors the door ajar switches, liftgate 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, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes. After 15 minutes 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 1789 DRB III. The system may be disarmed by either an unlock command from a valid RKE key fob or by using a key in the lift gate or either door. Both front door key cylinders and the lift gate 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. The RKE system is placed in the programming mode by the DRB, or by using the customer programming sequence. The system will store up to four key fob codes. Two fobs are supplied with the truck, additional fobs may be purchased through parts department. The additional fobs can be programmed with the DRB III, or by using the customer programming sequence. 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. Speed Sensitive Intermittent Wipers The DN truck equipped with a highine CTM will utilize speed sensitive intermittent wipers. Only a highine CTM Will be able to support this feature. A base CTM will provide for intermittent wipers without the speed sensitive feature. 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. Diagnostics The CTM is fully addressable with the DRB III and it is the recommended method for diagnosis. The CTM reports 6 Diagnostic Trouble Codes. All of the inputs to the CTM can be read with the DRB and the outputs can be actuated. VEHICLE COMMUNICATION The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, and is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measureable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network" located in the module that supplies bus bias or voltage. Along with the module that supplies bias, some modules provide termination. Bias is the voltage necessary to make the bus operational. At least one point of termination is necessary, some systems may use more than one. Some modules are capable of both biasing and terminating. Termination in the circuitry (a 120 ohm resistor placed across the bus) is required to complete the voltage divider network circuit and also provide some electromagnetic protection for the bus. In this vehicle, the bias is supplied by the instrument cluster and termination is provided by the PCM and the instrument cluster. Without termination, voltage on the bus goes to approximately 5 volts on one wire and 0 volts on the other wire. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB III. Problems with the operation of the bus or DRB III must corrected before proceeding with diagnostic testing. Bus Failure Messages Short to Battery - Either or both of the bus wires are shorted to the battery potential, or Open ground to any CCD bus module. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of the bus wires are shorted to ground. Bus (+) L Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with the Instrument Cluster. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 1790 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. The procedure begins with AIRBAG TEST 1A-Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. 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 for 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 occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. 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 the 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, the 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. Airbag Diagnostic Trouble Codes The airbag control module may report any of the following diagnostic trouble codes. For the following codes, replace the Airbag Control Module (ACM) even if set intermittently: ACM Accelerometer - Internal Diagnostic 1 - Internal Diagnostic 2 For the following codes, replace the Airbag Control Module (ACM): ACM Output Driver - ACM Stored Energy Logic - ACM Stored Energy Driver - ACM Stored Energy Passenger - Internal Diagnostic 3 - Internal Diagnostic 4 - Safing Sensor Shorted - Warning Lamp Driver Error For these codes, refer to the appropriate diagnostic procedure: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 1791 - Driver Squib Open - Driver Squib Shorted - Loss of Ignition Run Only - Loss of Ignition Run/Start - No CCD Communication - Passenger Squib Circuit Open - Passenger Squib Circuit Shorted - Either Squib Terminal Short to Battery - Either Squib Terminal Short to Ground - Warning Lamp Circuit Open - Warning Circuit Shorted Central Timer Module Diagnostic Trouble Codes - Door Disarm Switch Failure - Door Lock Switch Failure - Door Unlock Switch Failure - Wiper Park Switch Failure - EEPROM Checksum Failure - Internal ROM Test Failure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 AM/FM Switch Inoperative SYMPTOM AM-FM SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Balance Dial Inoperative SYMPTOM BALANCE DIAL INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative CD Eject Switch Inoperative SYMPTOM CD EJECT SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Equalizer Inoperative SYMPTOM EQUALIZER INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative External CD Changer (If Equipped) SYMPTOM * EXTERNAL CD CHANGER (IF EQUIPPED) POSSIBLE CAUSES - CD cable assembly defective - CD changer defective - Defective radio Fader Dial Inoperative SYMPTOM FADER DIAL INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative FF/RW Switch Inoperative SYMPTOM Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1794 FF/RW SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Hour/Minute Switch Inoperative SYMPTOM HOUR/MINUTE SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative No Sound From All Speakers SYMPTOM * NO SOUND FROM ALL SPEAKERS POSSIBLE CAUSES - Radio 12 V output circuit defective - Radio defective - Radio defective - Fused B(+) circuit open - Ground circuit open - Defective radio No Sound From One Speaker SYMPTOM * NO SOUND FROM ONE SPEAKER POSSIBLE CAUSES - Pillar speaker (+) circuit open - Pillar speaker (-) circuit open - Pillar speaker defective - Speaker (-) circuit shorted - Speaker defective - Amplifier speaker (+) circuit open - Amplifier speaker (-) circuit open - Power amplifier defective - Power amplifier defective Pause/Play Switch Inoperative SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Poor Sound Quality All Speakers SYMPTOM * POOR SOUND QUALITY ALL SPEAKERS POSSIBLE CAUSES - Antenna connector connection defective - Radio 12 V output circuit defective - Radio connections defective - Radio defective Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1795 - Radio defective - Fused B(+) circuit open - Ground circuit open - Radio choke relay connection defective Poor Sound Quality From One Speaker SYMPTOM * POOR SOUND QUALITY FROM ONE SPEAKER POSSIBLE CAUSES - Pillar/lower speaker (+) circuit open - Pillar lower speaker (-) circuit open - Pillar speaker defective - Radio defective - Radio defective - Speaker (+) circuit open - Speaker (-) circuit open - Speaker defective PWR Switch Inoperative SYMPTOM PWR SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Remote Steering Wheel Switches (If Equipped) SYMPTOM * REMOTE STEERING WHEEL SWITCHES (IF EQUIPPED) POSSIBLE CAUSES - MUX control clockspring defective - Radio control circuit defective open - Radio control switch ground circuit open - Radio MUX control circuit defective - Remote control switch defective - No response CCD bus failure - Radio control MUX circuit open - Central timer module defective Scan Switch Inoperative SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Seek Switch Inoperative SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1796 Set Switch Inoperative SYMPTOM SET SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Shorted Front Channel SYMPTOM SHORTED FRONT CHANNEL POSSIBLE CAUSES - Radio defective - Right front SPKR (+) circuit short to ground - Right front SPKR (-) circuit short to ground - Left front SPKR (+) circuit short to ground - Left front SPKR (-) circuit short to ground Shorted Left Channel SYMPTOM SHORTED LEFT CHANNEL POSSIBLE CAUSES - Left rear SPKR (+) circuit short to ground - Left rear SPKR (-) circuit short to ground - Left front SPKR (+) circuit short to ground - Left front SPKR (-) circuit short to ground - Radio defective Shorted Rear Channel SYMPTOM SHORTED REAR CHANNEL POSSIBLE CAUSES - Left rear SPKR (+) circuit short to ground - Left rear SPKR (-) circuit short to ground - Radio defective - Right rear SPKR (+) circuit short to ground - Right rear SPKR (-) circuit short to ground Shorted Right Channel SYMPTOM SHORTED RIGHT CHANNEL POSSIBLE CAUSES - Right rear SPKR (+) circuit short to ground - Right rear SPKR (-) circuit short to ground - Right front SPKR (+) circuit short to ground - Radio defective - Right front SPKR (-) circuit short to ground Tape Eject Switch Inoperative SYMPTOM TAPE EJECT SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1797 Tune Switch Inoperative SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Volume/Time Switch Inoperative SYMPTOM VOL/TIME SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative 1-5 Presets Inoperative SYMPTOM 1-5 PRESETS INOPERATIVE POSSIBLE CAUSES - Radio function controls inoperative Chime Inoperative - Engine Temperature Critical SYMPTOM * CHIME INOPERATIVE - ENGINE TEMPERATURE CRITICAL POSSIBLE CAUSES - Tone request circuit open - Instrument cluster tone request output defective - CTM fails chime test - PCM DTC - coolant temp check Chime Inoperative - Key In Ignition & LF Door Open SYMPTOM * CHIME INOPERATIVE - KEY IN IGNITION & LF DOOR OPEN POSSIBLE CAUSES - Key in ignition SW sense CKT open - Ignition SW-key in SW open - CTM no chime to key in ignition - CTM not responding to key in SW Chime Inoperative at All Times SYMPTOM * CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM fails internal chime test Chime Inoperative With Exterior Lamps On SYMPTOM * CHIME INOPERATIVE WITH EXTERIOR LAMPS ON POSSIBLE CAUSES - Headlamp switch circuit open Chime Inoperative With Low Oil Pressure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1798 SYMPTOM * CHIME INOPERATIVE WITH LOW OIL PRESSURE POSSIBLE CAUSES - Oil pressure sender ground circuit open - Tone request circuit open - Instrument cluster - oil press defective - CTM no response to oil pressure default - CTM fails chime test Chime Sounds With Driver Door Open SYMPTOM * CHIME SOUNDS WITH DRIVER DOOR OPEN POSSIBLE CAUSES - Key in ignition switch sense circuit short to ground - Ignition SW - key in SW shorted - CTM - key in sense short default - CTM not responding to key out Open Driver Door Ajar Circuit SYMPTOM * OPEN DRIVER DOOR AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Left front ajar switch sense circuit open - Left front door ajar switch defective shorted - Left front door ajar switch sense circuit open Open Gate Ajar Circuit SYMPTOM * OPEN GATE AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Liftgate ajar switch sense circuit defective open - Liftgate door ajar ground circuit defective open - Liftgate door ajar switch defective open Open Left Rear Door Ajar Circuit SYMPTOM * OPEN LEFT REAR DOOR AJAR CIRCUIT POSSIBLE CAUSES - Left rear door ajar switch sense circuit defective open - CTM defective - Ground circuit defective open - Left rear door ajar switch defective open Open Right Front Door Ajar Circuit SYMPTOM * OPEN RIGHT FRONT DOOR AJAR CIRCUIT POSSIBLE CAUSES - RF door ajar switch sense (ground circuit) open - Right front door ajar switch sense circuit open - CTM defective - Right front door ajar switch defective open Open Right Rear Door Ajar Circuit SYMPTOM * OPEN RIGHT REAR DOOR AJAR CIRCUIT Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1799 POSSIBLE CAUSES - Right rear door ajar switch sense circuit defective open - CTM defective - Ground circuit defective open - Right rear door ajar switch defective open Shorted Driver Door Ajar Circuit SYMPTOM * SHORTED DRIVER DOOR AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Left front door ajar switch defective shorted - LF door ajar switch sense circuit short to GND Shorted Gate Ajar Circuit SYMPTOM * SHORTED GATE AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Liftgate ajar switch defective shorted - Liftgate ajar switch sense circuit defective short to GND Shorted Passenger Door Ajar Circuit SYMPTOM * SHORTED PASSENGER DOOR AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Door ajar switch sense circuit short to ground - Right front door ajar switch defective shorted - Right rear door ajar switch DEF shorted - Left rear door ajar switch DEF shorted All Gauges Inoperative SYMPTOM * ALL GAUGES INOPERATIVE POSSIBLE CAUSES - No response/CCD bus (MIC) - Fuse #17 open - Fused ignition switch output circuit open - Instrument cluster defective Any CCD Cluster Warning Lamp Inoperative SYMPTOM * ANY CCD CLUSTER LAMP INOPERATIVE POSSIBLE CAUSES - No response/CCD bus (MIC) - CCD inoperative lamp/bulb defective - CCD lamp cluster input defective - Defective cluster - CCD LP cluster test complete Any Hard Wired Cluster Warning Lamp SYMPTOM * ANY HARD WIRED LAMP INOPERATIVE POSSIBLE CAUSES - Hard wired lamp circuit open Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1800 - Inoperative lamp/bulb defective - Defective instrument cluster One Gauge Not Operating Properly SYMPTOM * ONE GAUGE NOT OPERATING PROPERLY POSSIBLE CAUSES - Gauge not reading 4 PSI> engine warm at idle - Oil gauge not reading 4 PSI Or > at idle - Oil level low - Instrument cluster circuit board defective - Oil pressure sensor defective - Instrument cluster defective - Oil pressure sense circuit open - Oil pressure sense signal CKT short to ground - Cooling system operation faulty - DRB shows ECT sensor voltage too high - DRB shows ECT sensor voltage too low - Check for PCM DTC'S - Defective JTEC module - Fuel gauge inoperative - JTEC module defective - Oil pressure switch defective - Pinion factor incorrect - Powertrain control module defective - Tachometer inoperative - Voltage gauge inoperative Average MPH/Fuel Econ Inoperative or Wrong SYMPTOM * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG POSSIBLE CAUSES - Defective compass/mini-trip computer CMTC Display Shows Failed SYMPTOM * CMTC DISPLAY SHOWS FAILED POSSIBLE CAUSES - Defective CMTC display failed CMTC Fails to Respond to Instrument Panel Dimming SYMPTOM * CMTC FAILS TO RESPOND TO INSTRUMENT PANEL DIMMING TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer CMTC Segments Fail to Light Up SYMPTOM * CMTC SEGMENTS FAIL TO LIGHT UP POSSIBLE CAUSES - Defective compass mini-trip computer-segments fail to light Distance to Empty Inoperative or Wrong SYMPTOM * DISTANCE TO EMPTY INOPERATIVE OR WRONG Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1801 TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer Elapsed Time Inoperative/Wrong SYMPTOM * ELAPSED TIME INOPERATIVE/WRONG TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer Repairing OC In CMTC Display SYMPTOM * REPAIRING "OC" IN CMTC DISPLAY POSSIBLE CAUSES - Open sensor ground circuit - Defective ambient temperature sensor-SC - Open ambient temperature sensor signal circuit - Defective CMTM/OC default Repairing SC In CMTC Display SYMPTOM * REPAIRING "OC" IN CMTC DISPLAY POSSIBLE CAUSES - Ambient temperature sensor signal CKT-SH/sensor GND - Defective ambient temperature sensor-OC - Ambient temperature sensor signal CKT-short/GND - Defective CMTM/SC default Switch on Compass Mini-Trip Computer Inoperative SYMPTOM * SWITCH ON COMPASS MINI-TRIP COMPUTER INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer Trip Odometer Inoperative/Wrong SYMPTOM * TRIP ODOMETER INOPERATIVE/WRONG TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer Automatic (Rolling) Door Locks Inoperative SYMPTOM * AUTOMATIC (ROLLING) DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Link to body communication bus inoperative Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1802 - Speed sensing door locks inoperative Doors Lock With Key In Ignition and Left Door Open SYMPTOM * DOORS LOCK WITH KEY IN IGNITION AND LEFT DOOR OPEN POSSIBLE CAUSES - Link to body communication bus inoperative - Ignition switch shorted - Key-in ignition switch sense circuit open - CTM input A9 short to ground - CTM input shorted to ground One or All Doors Failing to Lock From One Switch SYMPTOM * ONE OR ALL DOORS FAILING TO LOCK FROM ONE SWITCH POSSIBLE CAUSES - Link to body communication bus inoperative - Door lock actuator assembly defective - Door unlock actuator assembly defective - Door lock switch assembly open - Door unlock switch assembly open - Door lock driver circuit open - Fused B (+) circuit open - Door lock driver circuit open - Power door lock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - CTM lock driver input open - CTM unlock driver input open - Lock driver circuit on CTM open - Unlock driver circuit on CTM open One or All Doors Failing to Unlock From One Switch SYMPTOM * ONE OR ALL DOORS FAILING TO UNLOCK FROM ONE SWITCH TEST NOTE: This symptom is diagnosed using the test * ONE OR ALL DOORS FAILING TO LOCK FROM ONE SWITCH. POSSIBLE CAUSES - Link to body communication bus inoperative - Door lock actuator assembly defective - Door unlock actuator assembly defective - Door lock switch assembly open - Door unlock switch assembly open - Door lock driver circuit open - Fused B (+) circuit open - Door lock driver circuit open - Power door lock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - CTM lock driver input open - CTM unlock driver input open - Lock driver circuit on CTM open - Unlock driver circuit on CTM open Remote Keyless Entry Problem SYMPTOM * REMOTE KEYLESS ENTRY PROBLEM POSSIBLE CAUSES - Link to body communication bus inoperative Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1803 - Transmitter defective - Circuit between CTM & left front UNLCK RLY open - Door unlock relay defective - Door unlock relay internal defect - Left front door unlock relay coil out of tolerance - Left front door unlock relay B (+) circuit open - Unlock relay B (+) circuit open (CAV 87) - CTM defective-RKE function - CTM unlock relay signal inoperative - Left front door unlock relay circuit at CTM open Intermittent Wipers Inoperative SYMPTOM * INTERMITTENT WIPERS INOPERATIVE POSSIBLE CAUSES - No response/CCD bus failure - CTM - Open intermittent wiper mode sense CKT - Open wiper park switch sense CKT - Defective wiper motor/12 volts - Defective CTM/12 volt default - Defective CTM/STALK switch - Defective multi-function switch/5.0 ohms No Wipe After Washers Actuated SYMPTOM * NO WIPE AFTER WASHERS ACTUATED POSSIBLE CAUSES - CCD bus failure-no response CTM - Open front washer switch sensor CKT - Defective CTM/washer pump Wiper Speed Sensitive Feature Inoperative SYMPTOM * WIPER SPEED SENSITIVE FEATURE INOPERATIVE POSSIBLE CAUSES - CCD bus failure-CTM - CCD bus failure PCM - Defective CTM/wiper intervals Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1804 Central Timer Module: Component Tests and General Diagnostics 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 SCREEN WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1805 Central Timer Module: Scan Tool Testing and Procedures Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, recored the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key itf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III Does Not Power Up (blank Screen) 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. Perform the "DRB Blank Screen" test under Vehicle Communication. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Information Bus/DRB Blank Screen DRB III Display Is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1806 Central Timer Module: Tools and Equipment DRB III (Diagnostic Read Out Box) Jumper Wires Ohmmeter Voltmeter Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Specifications Powertrain Control Module: Specifications Powertrain Control Module Mounting Screws 1 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Specifications > Page 1810 Powertrain Control Module: Locations PCM Location And Mounting Powertrain Control Module The PCM is located in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1813 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1814 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1815 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1816 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1817 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1818 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1819 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1820 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1821 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1822 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1823 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1824 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1825 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1826 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1827 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1828 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1829 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1830 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1831 Powertrain Control Module: Connector Views Powertrain Control Module C1 Powertrain Control Module C2 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1832 Powertrain Control Module C3 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1833 Powertrain Control Module: Service and Repair PCM Location And Mounting The PCM is located in the engine compartment. REMOVAL 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 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. IMPORTANT NOTE: If the Powertrain Control Module has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the ABS and Air bag modules. In addition, if the vehicle is equipped with a Sentry Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. FOR ABS AND AIR BAG SYSTEMS: 1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS and Air Bag modules. FOR SKIM THEFT ALARM: 1. Connect the DRBIII to the data link connector. 2. Go to Theft Alarm, SKIM, Misc. and place the SKIM in secured access mode, by using the appropriate PIN code for this vehicle. 3. Select Update the Secret Key data, data will be transferred from the SKIM to the PCM (This is required to allow the vehicle to start with the new PCM). 4. If three attempts are made to enter secured access mode using the incorrect PIN, secured access mode will be locked out for one hour. To exit this lock out mode, leave the ignition key in the Run/Start position for one hour. Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Power Distributor Center (PDC) Location Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1837 Power Distribution Center The ASD relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1838 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down (ASD) Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1839 Automatic Shut Down (ASD) Relay: Description and Operation AUTOMATIC SHUTDOWN (ASD) RELAY SENSE-PCM INPUT Power Distribution Center(PDC) A 12 volt signal at this input indicates to the Powertrain Control Module (PCM) that the ASD has been activated. The ASD relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. 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 PCM does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). AUTO SHUTDOWN (ASD) RELAY-PCM OUTPUT The ASD relay is located in the Power Distribution Center (PDC). The ASD supplies battery voltage to the fuel injectors, ignition coil and oxygen (O2S) sensor heating elements. The ground circuit for the coil in the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the relay by switching the ground circuit on and off. AUTOMATIC SHUTDOWN (ASD) RELAY As one of its functions, the ASD relay will supply battery voltage to the ignition coil. The ground circuit for the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM regulates ASD relay operation by switching the ground circuit on-and-off. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1840 Automatic Shut Down (ASD) Relay: Testing and Inspection ASD And Fuel Pump Relay Terminals 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. Operation 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. Testing The following procedure applies to the ASD and fuel pump relays. 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 ± 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 source5 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1841 Automatic Shut Down (ASD) Relay: Service and Repair Power Distributor Center (PDC) Location The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. REMOVAL 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 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Distributor Center (PDC) Location Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1846 Power Distribution Center The fuel pump relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1847 Fuel Pump Relay: Diagrams Power Distribution Center Fuel Pump Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1848 Fuel Pump Relay: Description and Operation FUEL PUMP RELAY-PCM OUTPUT The PCM energizes the electric fuel pump through the fuel pump relay. Battery voltage is applied to the fuel pump relay when the ignition key is ON. The relay is energized when a ground signal is provided by the PCM. The fuel pump will operate for approximately one second unless the engine is operating or the starter motor is engaged. The fuel pump relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1849 Fuel Pump Relay: Testing and Inspection ASD And Fuel Pump Relay Terminals 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. Operation 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. Testing The following procedure applies to the ASD and fuel pump relays. 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 ± 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 source5 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1850 Fuel Pump Relay: Service and Repair Power Distributor Center (PDC) Location The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. REMOVAL 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 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Power Distributor Center (PDC) Location Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1854 Power Distribution Center The ASD relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1855 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down (ASD) Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1856 Automatic Shut Down (ASD) Relay: Description and Operation AUTOMATIC SHUTDOWN (ASD) RELAY SENSE-PCM INPUT Power Distribution Center(PDC) A 12 volt signal at this input indicates to the Powertrain Control Module (PCM) that the ASD has been activated. The ASD relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. 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 PCM does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). AUTO SHUTDOWN (ASD) RELAY-PCM OUTPUT The ASD relay is located in the Power Distribution Center (PDC). The ASD supplies battery voltage to the fuel injectors, ignition coil and oxygen (O2S) sensor heating elements. The ground circuit for the coil in the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the relay by switching the ground circuit on and off. AUTOMATIC SHUTDOWN (ASD) RELAY As one of its functions, the ASD relay will supply battery voltage to the ignition coil. The ground circuit for the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM regulates ASD relay operation by switching the ground circuit on-and-off. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1857 Automatic Shut Down (ASD) Relay: Testing and Inspection ASD And Fuel Pump Relay Terminals 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. Operation 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. Testing The following procedure applies to the ASD and fuel pump relays. 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 ± 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 source5 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1858 Automatic Shut Down (ASD) Relay: Service and Repair Power Distributor Center (PDC) Location The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. REMOVAL 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 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 1863 Ignition Relay: Diagrams Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 1864 Horn, Ignition (Max Cooling) & Trailer Tow Relays Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Battery Temperature Sensor The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1870 Battery Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1871 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1872 Battery Temperature Sensor: Description and Operation DESCRIPTION The battery temperature sensor is attached to the battery tray located under the battery. OPERATION The battery temperature sensor 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. BATTERY TEMPERATURE SENSOR-PCM INPUT Provides a signal to the PCM corresponding to the battery temperature. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor 1. The sensor is located on the front of the battery tray. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25° C (75-80° F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 1875 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. REMOVAL 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor Oil Pressure Sending Unit/Switch, Camshaft Position Sensor Connector The camshaft position sensor is located in the distributor on all engines. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1879 Camshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1880 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor CAMSHAFT POSITION SENSOR - PCM INPUT A sync signal is provide by the camshaft position sensor located in the distributor. The sync signal from this sensor works in conjunction with the crankshaft position sensor to provide the Powertrain Control Module (PCM) with inputs. This is done to establish and maintain correct injector firing order. CAMSHAFT POSITION SENSOR The camshaft position sensor is located in the distributor on all engines. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1881 Camshaft Position Sensor: Testing and Inspection Camshaft Position Sensor The camshaft position sensor is located in the distributor on all engines. To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: For this test, an analog (non-digital) voltmeter is needed. Do not remove the distributor connector from the distributor. Using small paper clips, insert them into the backside of the distributor wire harness connector to make contact with the terminals. Be sure that the connector is not damaged when inserting the paper clips. Attach voltmeter leads to these paper clips. 1. Connect the positive (+) voltmeter lead into the sensor output wire. This is at done the distributor wire harness connector. 2. Connect the negative (-) voltmeter lead into the ground wire. 3. Set the voltmeter to the 15 Volt DC scale. 4. Remove distributor cap from distributor (two screws). Rotate (crank) the engine until the distributor rotor is pointed towards the rear of vehicle. The movable pulse ring should now be within the sensor pickup. 5. Turn ignition key to ON position. Voltmeter should read approximately 5.0 volts. 6. If voltage is not present, check the voltmeter leads for a good connection. 7. If voltage is still not present, check for voltage at the supply wire. For wire identification, refer to Wiring Diagrams. 8. If 5 volts is not present at supply wire, check for voltage at PCM 32-way connector (cavity A-17). Leave the PCM connector connected for this test. 9. If voltage is still not present, perform vehicle test using the DRB scan tool. 10. If voltage is present at cavity A-17, but not at the supply wire: a. Check continuity between the supply wire. This is checked between the distributor connector and cavity A-17 at the PCM. If continuity is not present, repair the harness as necessary. b. Check for continuity between the camshaft position sensor output wire and cavity A-18 at the PCM, If continuity is not present, repair the harness as necessary. c. Check for continuity between the ground circuit wire at the distributor connector and ground. If continuity is not present, repair the harness as necessary. 11. While observing the voltmeter, crank the engine with ignition switch. The voltmeter needle should fluctuate between 0 and 5 volts while the engine is cranking. This verifies that the camshaft position sensor in the distributor is operating properly and a sync pulse signal is being generated. If sync pulse signal is not present, replacement of the camshaft position sensor is necessary Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1882 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor The camshaft position sensor is located in the distributor on all engines. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove air cleaner assembly. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. tighten mounting screws. 5. Install air cleaner assembly. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 11 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1886 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor-Typical Intake Air Temperature Sensor, Engine Coolant Temperature Sensor Connector, Ignition Coil The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1887 Engine Coolant Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1888 Coolant Temperature Sensor/Switch (For Computer): Service Precautions WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1889 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT The engine coolant temperature sensor is installed into a water jacket at the front of the intake manifold located near the rear of the generator. The sensor provides an input voltage to the Powertrain Control Module (PCM) relating coolant temperature. The PCM uses this input along with inputs from other sensors to determine injector pulse width and ignition timing. As coolant temperature varies, the coolant temperature sensor resistance will change. This change in resistance results in a different input voltage to the PCM. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1890 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: Engine Coolant Temperature Sensor-Typical 1. Disconnect wire harness connector from coolant temperature sensor. 2. Engines with air conditioning: When removing the connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place the hook part of tool under the connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. Sensor Resistance(Ohms)-Coolant Temperature Sensor/Intake Air Temperature Sensor 3. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. The resistance (as measured across the sensor terminals) should be as shown in the SENSOR RESISTANCE (OHMS)-COOLANT TEMPERATURE SENSOR/INTAKE AIR TEMPERATURE SENSOR resistance chart. Replace the sensor if it is not within the range of resistance specified in the chart. 4. Test continuity of the wire harness between the PCM wire harness connector and the coolant sensor connector terminals. Refer to Wiring for terminal/cavity locations. Repair the wire harness if an open circuit is indicated. 5. After tests are completed, connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1891 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor-Typical The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain cooling system. 2. Disconnect electrical connector from sensor. 3. Engines with air conditioning: When removing the connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place the hook part of tool under the connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Use long needle nose pliers to connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. 4. Replace any lost engine coolant. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor 8 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1895 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The sensor is bolted to the cylinder block near the rear of the right cylinder head. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1896 Crankshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1897 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR 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. Sensor Operation The flywheel/drive plate has 8 single notches, spaced every 45 degrees, 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. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a crankshaft position sensor input. CRANKSHAFT POSITION SENSOR-PCM INPUT This sensor is a hall effect device that detects notches in the flywheel (manual transmission) or flexplate (automatic transmission). This sensor is used to indicate to the Powertrain Control Module (PCM) that a spark and or fuel injection event is to be required. The output from this sensor, in conjunction with the camshaft position sensor signal, is used to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1898 Crankshaft Position Sensor The sensor is bolted to the cylinder block near the rear of the right cylinder head. Refer to Ignition System for more crankshaft position sensor information. The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1899 Crankshaft Position Sensor: Testing and Inspection To perform a complete test of this sensor and its circuitry, refer to the DRB scan tool. Also refer to the appropriate Powertrain Diagnostics Procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1900 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. 1. Remove right front tire and right front wheelhouse liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheelhouse liner. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR-PCM INPUT The Powertrain Control Module (PCM) supplies power to the fuel level sensor (fuel gauge sending unit). The fuel level sensor will then return a signal to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes. This is if the fuel level is less than approximately 15 percent, or, if equipped with a Leak Detection Pump (LDP), more than approximately 85 percent of its rated capacity. This input is also used to send a signal to the PCM for fuel gauge operation via the CCD bus circuits. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Intake Manifold Air Temperature Sensor 28 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 1907 Intake Air Temperature Sensor: Locations Intake Manifold Air Temperature Sensor-Typical Intake Air Temperature Sensor, Engine Coolant Temperature Sensor Connector, Ignition Coil The intake manifold air temperature sensor is located in the front/side of the intake manifold. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 1908 Intake Air Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 1909 Intake Air Temperature Sensor: Description and Operation Intake Manifold Air Temperature Sensor INTAKE MANIFOLD AIR TEMPERATURE SENSOR-PCM INPUT The intake manifold air temperature sensor is installed in the intake manifold with the sensor element extending into the air stream. The sensor provides an input voltage to the Powertrain Control Module (PCM) indicating intake manifold air temperature. The input is used along with inputs from other sensors to determine injector pulse width. As the temperature of the air-fuel stream in the manifold varies, the sensor resistance changes. This results in a different input voltage to the PCM. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 1910 Intake Air Temperature Sensor: Testing and Inspection To perform a complete test of the intake manifold air temperature sensor and its circuitry, refer to DRB tester and appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: Intake Manifold Air Temperature Sensor 1. Disconnect the wire harness connector from the intake manifold air temperature sensor. Sensor Resistance(Ohms)-Coolant Temperature Sensor/Intake Air Temperature Sensor 2. Test the resistance of the sensor with an input impedance (digital) volt-ohmmeter. The resistance (as measured across the sensor terminals) should be as shown in the previous SENSOR RESISTANCE (OHMS-COOLANT TEMPERATURE SENSOR/INTAKE AIR TEMPERATURE SENSOR chart. Replace the sensor if it is not within the range of resistance specified in the chart. 3. Test the resistance of the wire harness. Do this between the PCM wire harness connector A-15 and the sensor connector terminal. Also check between PCM connector A-4 to the sensor connector terminal. Repair the wire harness as necessary if the resistance is greater than 1 ohm. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 1911 Intake Air Temperature Sensor: Service and Repair Intake Manifold Air Temperature Sensor-Typical The intake manifold air temperature sensor is located in the front/side of the intake manifold. REMOVAL 1. Remove air duct at throttle body. 2. Disconnect electrical connector at sensor 3. Remove sensor from intake manifold. INSTALLATION 1. Install sensor to intake manifold. Tighten to 28 Nm (20 ft. lbs.) torque. 2. Install electrical connector. 3. Install air duct at throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications MAP Sensor Mounting Screws 3 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1915 Manifold Pressure/Vacuum Sensor: Locations MAP And Throttle Position Sensor Location The MAP sensor is mounted on the side of the engine throttle body. The sensor is connected to the throttle body with a rubber L-shaped fitting. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1916 Manifold Absolute Pressure Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1917 Manifold Pressure/Vacuum Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR-PCM INPUT The MAP sensor reacts to absolute pressure in the intake manifold. It provides an input voltage to the Powertrain Control Module (PCM). As engine load changes, manifold pressure varies. The change in manifold pressure causes MAP sensor voltage to change. The change in MAP sensor voltage results in a different input voltage to the PCM. The input voltage level supplies the PCM with information about ambient barometric pressure during engine start-up (cranking) and engine load while the engine is running. The PCM uses this input along with inputs from other sensors to adjust air-fuel mixture. MAP And Throttle Position Sensor Location The MAP sensor is mounted on the side of the engine throttle body. The sensor is connected to the throttle body with a rubber L-shaped fitting. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1918 Manifold Pressure/Vacuum Sensor: Testing and Inspection MAP Sensor-Typical To perform a complete test of MAP sensor and its circuitry, refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the MAP sensor only, refer to the following: Rubber L-shaped Fitting-MAP Sensor-to-Throttle Body 1. Inspect the rubber L-shaped fitting from the MAP sensor to the throttle body. Repair as necessary. CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1919 MAP Sensor Connector Terminals-Typical 2. Test the MAP sensor output voltage at the MAP sensor connector between terminals A and B. With the ignition switch ON and the engine OFF, output voltage should be 4-to-5 volts. The voltage should drop to 1.5-to-2.1 volts with a hot, neutral idle speed condition. 3. Test Powertrain Control Module (PCM) cavity A-27 for the same voltage described above to verify the wire harness condition. Repair as necessary. 4. Test MAP sensor supply voltage at sensor connector between terminals A and C with the ignition ON. The voltage should be approximately 5 volts (± 0.5V). Five volts (± 0.5V) should also be at cavity A-17 of the PCM wire harness connector. Repair or replace the wire harness as necessary. 5. Test the MAP sensor ground circuit at sensor connector terminal-A and PCM connector A-4. Repair the wire harness if necessary Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1920 Manifold Pressure/Vacuum Sensor: Service and Repair MAP Sensor Location MAP Sensor L-Shaped Rubber Fitting The MAP sensor is located on the front of the throttle body. An L-shaped rubber fitting is used to connect the MAP sensor to throttle body. REMOVAL 1. Remove air duct at throttle body. 2. Remove two MAP sensor mounting bolts (screws). 3. While removing MAP sensor, slide the vacuum rubber L-shaped fitting from the throttle body. 4. Remove rubber L-shaped fitting from MAP sensor. INSTALLATION 1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple. 3. Install MAP sensor mounting bolts (screws). Tighten screws to 3 Nm (25 in. lbs.) torque. 4. Install air duct at throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 1924 Oil Pressure Sensor: Description and Operation OIL PRESSURE SENSOR-PCM INPUT Sends a signal from the oil pressure sending unit to the Powertrain Control Module (PCM) relating to engine oil pressure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 1930 Oxygen Sensor: Locations Oxygen Sensor(s) Upstream Oxygen Sensor Locations Oxygen Sensor The upstream O2S sensor is located on exhaust downpipe. Downstream Oxygen Sensor Location Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 1931 Downstream Oxygen Sensor The downstream O2S sensor is located on the outlet end of the catalytic converter. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1932 Oxygen Sensor: Diagrams Oxygen Sensor (Sensor Side) Oxygen Sensor 1/1 Upstream Oxygen Sensor 1/2 Downstream Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1933 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1934 Oxygen Sensor: Application and ID Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1935 Oxygen Sensor: Description and Operation OXYGEN SENSOR-PCM INPUT Two heated O2S sensors are used. The sensors produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel mixture), the sensors produces a low voltage. When there is a lesser amount present (rich air/fuel mixture) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. In Closed Loop operation, the PCM monitors the 02S sensor input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the 02 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. 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. The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. UPSTREAM HEATED OXYGEN SENSOR The upstream O2S sensor is located near the inlet end of the catalytic converter. It 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 the air/fuel ratio by adjusting injector pulse width. DOWNSTREAM HEATED OXYGEN SENSOR The downstream heated oxygen sensor is located near the outlet end of the catalytic converter. The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the Malfunction Indicator Lamp (MIL). For more information, refer to Emission Control Systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1936 Oxygen Sensor: Testing and Inspection To perform a complete test of the 02S sensors and their circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the O2S sensors only, refer to the following: Upstream Oxygen Sensor Location The upstream O2S sensor is located on the exhaust pipe. Downstream Oxygen Sensor Location The downstream O2S sensor is located on the outlet end of the catalytic converter. Each O2S heating element can be tested with an ohmmeter as follows: Disconnect the O2S sensor connector. Connect the ohmmeter test leads across the white wire terminals of the sensor connector. Resistance should be between 4.5 ± 0.5 ohms and 7 ohms. Replace the sensor if the ohmmeter displays an infinity (open) reading. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1937 Oxygen Sensor: Service and Repair Upstream Oxygen Sensor Locations Downstream Oxygen Sensor Locations The upstream O2S sensor is located on exhaust downpipe. The downstream sensor is located near outlet end of catalytic converter. REMOVAL WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support the vehicle. 2. Disconnect the wire connector from the O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install the O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1941 Throttle Position Sensor: Locations MAP And Throttle Position Sensor Location The throttle position sensor (TPS) is mounted on the throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1942 Throttle Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1943 Throttle Position Sensor: Description and Operation MAP And Throttle Position Sensor Location THROTTLE POSITION SENSOR (TPS)-PCM INPUT The throttle position sensor (TPS) is mounted on the throttle body. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents throttle blade position. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1944 Throttle Position Sensor: Testing and Inspection To perform a complete test of the TPS and its circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the TPS only, refer to the following: Throttle Position Sensor The TPS can be tested with a digital voltmeter. The center electrical terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). At idle, TPS output voltage should be greater than 0.26 volts but less than 0.95 volts. At wide open throttle, TPS output voltage must be less than 4.49 volts. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1945 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on side of throttle body. 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body. INSTALLATION Installation-Typical The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1949 Transmission Position Switch/Sensor: Description and Operation TRANSMISSION PARK/NEUTRAL SWITCH-PCM INPUT The park/neutral switch is located on the transmission housing and provides an input to the Powertrain Control Module (PCM), This will indicate that the automatic transmission is in Park, Neutral or a drive gear selection. This input is used to determine idle speed (varying with gear selection), fuel injector pulse width, ignition timing advance and vehicle speed control operation. The center terminal of the park/neutral position switch is the starter-circuit terminal. It provides the ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. The outer terminals on the switch are for the backup lamp circuit. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1950 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for speed control system operation. For the location of the transmission output shaft sensor, please refer to Transmission Speed Sensor/Locations. See: Transmission Control Systems/Sensors and Switches - Transmission and Drivetrain/Sensors and Switches - A/T/Transmission Speed Sensor For the location of the rear wheel speed sensor, please refer to Brakes and Traction Control/Brakes/Antilock Brake System/Wheel Speed Sensor/Locations. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1956 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1957 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1958 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1959 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1960 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1961 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1962 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1963 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1964 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1965 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1966 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1967 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1968 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1969 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1970 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1971 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1972 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1973 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1974 Vehicle Speed Sensor: Description and Operation VEHICLE SPEED AND DISTANCE-PCM INPUT Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for fuel system and speed control system operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1979 Throttle Position Sensor: Locations MAP And Throttle Position Sensor Location The throttle position sensor (TPS) is mounted on the throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1980 Throttle Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1981 Throttle Position Sensor: Description and Operation MAP And Throttle Position Sensor Location THROTTLE POSITION SENSOR (TPS)-PCM INPUT The throttle position sensor (TPS) is mounted on the throttle body. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents throttle blade position. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1982 Throttle Position Sensor: Testing and Inspection To perform a complete test of the TPS and its circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the TPS only, refer to the following: Throttle Position Sensor The TPS can be tested with a digital voltmeter. The center electrical terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). At idle, TPS output voltage should be greater than 0.26 volts but less than 0.95 volts. At wide open throttle, TPS output voltage must be less than 4.49 volts. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 1983 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on side of throttle body. 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body. INSTALLATION Installation-Typical The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor Oil Pressure Sending Unit/Switch, Camshaft Position Sensor Connector The camshaft position sensor is located in the distributor on all engines. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1988 Camshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1989 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor CAMSHAFT POSITION SENSOR - PCM INPUT A sync signal is provide by the camshaft position sensor located in the distributor. The sync signal from this sensor works in conjunction with the crankshaft position sensor to provide the Powertrain Control Module (PCM) with inputs. This is done to establish and maintain correct injector firing order. CAMSHAFT POSITION SENSOR The camshaft position sensor is located in the distributor on all engines. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1990 Camshaft Position Sensor: Testing and Inspection Camshaft Position Sensor The camshaft position sensor is located in the distributor on all engines. To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: For this test, an analog (non-digital) voltmeter is needed. Do not remove the distributor connector from the distributor. Using small paper clips, insert them into the backside of the distributor wire harness connector to make contact with the terminals. Be sure that the connector is not damaged when inserting the paper clips. Attach voltmeter leads to these paper clips. 1. Connect the positive (+) voltmeter lead into the sensor output wire. This is at done the distributor wire harness connector. 2. Connect the negative (-) voltmeter lead into the ground wire. 3. Set the voltmeter to the 15 Volt DC scale. 4. Remove distributor cap from distributor (two screws). Rotate (crank) the engine until the distributor rotor is pointed towards the rear of vehicle. The movable pulse ring should now be within the sensor pickup. 5. Turn ignition key to ON position. Voltmeter should read approximately 5.0 volts. 6. If voltage is not present, check the voltmeter leads for a good connection. 7. If voltage is still not present, check for voltage at the supply wire. For wire identification, refer to Wiring Diagrams. 8. If 5 volts is not present at supply wire, check for voltage at PCM 32-way connector (cavity A-17). Leave the PCM connector connected for this test. 9. If voltage is still not present, perform vehicle test using the DRB scan tool. 10. If voltage is present at cavity A-17, but not at the supply wire: a. Check continuity between the supply wire. This is checked between the distributor connector and cavity A-17 at the PCM. If continuity is not present, repair the harness as necessary. b. Check for continuity between the camshaft position sensor output wire and cavity A-18 at the PCM, If continuity is not present, repair the harness as necessary. c. Check for continuity between the ground circuit wire at the distributor connector and ground. If continuity is not present, repair the harness as necessary. 11. While observing the voltmeter, crank the engine with ignition switch. The voltmeter needle should fluctuate between 0 and 5 volts while the engine is cranking. This verifies that the camshaft position sensor in the distributor is operating properly and a sync pulse signal is being generated. If sync pulse signal is not present, replacement of the camshaft position sensor is necessary Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1991 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor The camshaft position sensor is located in the distributor on all engines. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove air cleaner assembly. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. tighten mounting screws. 5. Install air cleaner assembly. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor 8 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1995 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The sensor is bolted to the cylinder block near the rear of the right cylinder head. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1996 Crankshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1997 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR 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. Sensor Operation The flywheel/drive plate has 8 single notches, spaced every 45 degrees, 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. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a crankshaft position sensor input. CRANKSHAFT POSITION SENSOR-PCM INPUT This sensor is a hall effect device that detects notches in the flywheel (manual transmission) or flexplate (automatic transmission). This sensor is used to indicate to the Powertrain Control Module (PCM) that a spark and or fuel injection event is to be required. The output from this sensor, in conjunction with the camshaft position sensor signal, is used to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1998 Crankshaft Position Sensor The sensor is bolted to the cylinder block near the rear of the right cylinder head. Refer to Ignition System for more crankshaft position sensor information. The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1999 Crankshaft Position Sensor: Testing and Inspection To perform a complete test of this sensor and its circuitry, refer to the DRB scan tool. Also refer to the appropriate Powertrain Diagnostics Procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2000 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. 1. Remove right front tire and right front wheelhouse liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheelhouse liner. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Removal/Installation. On vehicles equipped with an automatic transmission and a steering column mounted shifter an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced.. On vehicles equipped with an automatic transmission and a floor mounted shifter , a cable connects the interlock device within the steering column assembly, to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. The shifter interlock cable can be adjusted or replaced. SYSTEM DESCRIPTION The key-in ignition switch is integral to the ignition switch, which is mounted on the right side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition lock cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition lock cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 2005 Ignition Switch Lock Cylinder: Service and Repair The ignition key must be in the key cylinder for cylinder removal. REMOVAL 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. Shroud Removal/Installation - Typical 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Retaining Pin 5. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 2006 Flag In RUN Position Key Cylinder-Rear View Switch Mounting Screws 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 2007 Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed. 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Ignition Switch View From Column Park Lock Linkage-Automatic Transmission-Typical Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 2008 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkage before installing switch. Steering Wheel Lock Lever 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 3 Nm ± 0.5 Nm (26 in. lbs. ± 4 in. lbs.) torque. 11. Connect electrical connectors to ignition switch and halo lamp. Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). Tighten screws to 2 Nm (17 in. lbs.) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery. 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY; LOCK, OFF, ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify. Steering wheel should unlock when key is rotated to ON position. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Testing Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle ......................................................................................................................... ......................................................... 500 to 900 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2017 Idle Speed: Testing and Inspection The following test procedure has been developed to check throttle body calibrations for correct idle conditions. The procedure should be used to diagnose the throttle body for conditions that may cause idle problems. This procedure should be used only after normal diagnostic procedures have failed to produce results that indicate a throttle body related problem. Be sure to check for proper operation of the idle air control motor before performing this test. Fixed Orifice Tool A special fixed orifice tool (number 6714) must be used for the following test. 1. Start the engine and bring to operating temperature. Be sure all accessories are off before performing this test. 2. Shut off the engine and remove the air duct at throttle body. Install Orifice Tool 3. Disconnect the vacuum line at the PCV valve. 4. Install the 0.185 inch orifice tool (number 6714) into the disconnected vacuum line in place of the PCV valve. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2018 Idle Purge Line 5. Disconnect the idle purge vacuum line from fitting at throttle body. This vacuum line is located on the front of throttle body next to the MAP sensor. Cap the fitting at throttle body after vacuum line has been removed. 6. Connect the DRB scan tool to the 16-way data link connector. This connector is located under the instrument panel to the left of the steering column. Refer to the appropriate Powertrain Diagnostic Procedures service for DRB operation. 7. Start the engine and allow to warm up. 8. Using the DRB scan tool, scroll through the menus as follows: select-Stand Alone DRB III, select 1999 Diagnostics, select-Engine, select-System Test, select-Minimum Air Flow. 9. The DRB scan tool will count down to stabilize the idle rpm and display the minimum air flow idle rpm. The idle rpm should be between 500 and 900 rpm. If the idle speed is outside of these specifications, replace the throttle body. Refer to Throttle Body in the Component Removal/Installation. 10. Disconnect the DRB scan tool from the vehicle. 11. Remove cap from idle purge fitting at throttle body and install vacuum line. 12. Remove orifice tool and connect vacuum line to PCV valve. 13. Install air duct to throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Air Cleaner Housing Assembly 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 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Use following procedure if fuel rail is or is not equipped with fuel pressure test port. 1. Remove fuel fill cap. 2. The fuel filler tube contains a spring-loaded flap (door) located below fuel fill cap. The flap is used as a secondary way of sealing fuel tank if fuel fill cap has not been properly tightened. It is part of EVAP monitor system when vehicle is equipped with a Leak Detection Pump (LDP). The vehicle may be equipped with flap installed into fuel filler tube even though vehicle is not equipped with LDP and EVAP monitor system. Place a nonmetallic object into fuel fill tube and press on flap to relieve any tank pressure. 3. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. 6. 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. 7. Unplug connector from any injector. 8. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 9. Connect other end of jumper wire to positive side of battery. 10. 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. 11. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 12. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 13. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 14. Return fuel pump relay to PDC. 15. 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. Refer to Emission Control System. See On-Board Diagnostics. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2042 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2043 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2044 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2045 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2046 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2047 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2053 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2054 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2055 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2056 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2057 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2058 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2059 Ignition Cable: Specifications Spark Plug Cable Resistance Minimum 250 ohms 3000 ohms Maximum 1000 ohms 12000 ohms Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2060 Ignition Cable: Description and Operation Spark plug cables are sometimes referred to as secondary ignition wires. These cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2061 Ignition Cable: Testing and Inspection Check the spark plug cable connections for good contact at the coil(s), distributor cap towers, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, distributor and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean high voltage ignition cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. Head Shields On all engines, spark plug cable heat shields are pressed into the cylinder head to surround each spark plug cable boot and spark plug. These shields protect the spark plug boots from damage (due to intense engine heat generated by the exhaust manifolds) and should not be removed. After the spark plug cable has been installed, the lip of the cable boot should have a small air gap to the top of the heat shield. Testing When testing secondary cables for damage with an oscilloscope, follow the instructions of the equipment manufacturer. If an oscilloscope is not available, spark plug cables may be tested as follows: CAUTION: Do not leave any one spark plug cable disconnected for longer than necessary during testing. This may cause possible heat damage to the catalytic converter. Total test time must not exceed ten minutes. With the engine running, remove spark plug cable from spark plug (one at a time) and hold next to a good engine ground. If the cable and spark plug are in good condition, the engine rpm should drop and the engine will run poorly. If engine rpm does not drop, the cable and/or spark plug may not be operating properly and should be replaced. Also check engine cylinder compression. With the engine not running, connect one end of a test probe to a good ground. Start the engine and run the other end of the test probe along the entire length of all spark plug cables. If cables are cracked or punctured, there will be a noticeable spark jump from the damaged area to the test probe. The cable running from the ignition coil to the distributor cap can be checked in the same manner. Cracked, damaged or faulty cables should be replaced with resistance type cable. This can be identified by the words ELECTRONIC SUPPRESSION printed on the cable jacket. Use an ohmmeter to test for open circuits, excessive resistance or loose terminals. If equipped, remove the distributor cap from the distributor. Do not remove cables from cap. Remove cable from spark plug. Connect ohmmeter to spark plug terminal end of cable and to corresponding electrode in distributor cap. Resistance should be 250 to 1000 Ohms per inch of cable. If not, remove cable from distributor cap tower and connect ohmmeter to the terminal ends of cable. If resistance is not within specifications as found in the SPARK PLUG CABLE RESISTANCE chart, replace the cable. Test all spark plug cables in this manner. SPARK PLUG CABLE RESISTANCE MINIMUM = MAXIMUM 250 Ohms Per Inch = 1000 Ohms Per Inch 3000 Ohms Per Foot = 12,000 Ohms Per Foot Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2062 Ignition Cable: Service and Repair REMOVAL AND INSTALLATION Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. Engine Firing Order Install cables into the proper engine cylinder firing order. When replacing the spark plug and coil cables, route the cables correctly and secure in the proper retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause cross ignition of the plugs or short circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and the distributor cap tower. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Cap Inspection - External - Typical Cap Inspection-Internal-Typical Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the inside (caused by condensation entering the cap through cracks). Replace any cap that displays charred or eroded terminals. The machined surface of a terminal end (faces toward rotor) will indicate some evidence of erosion from normal operation. Examine the terminal ends for evidence of mechanical interference with the rotor tip. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Rotor Inspection - Typical Visually inspect the rotor for cracks, evidence of corrosion or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on the end of the metal tip. The silicone-dielectric- varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap 0.040 in Torque 30 ft lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2073 Spark Plug: Application and ID Plug Type ............................................................................................................................................ .................................................................... RC12LC4 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2074 Spark Plug: Description and Operation All engines use resistor type spark plugs. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Spark plugs that have low milage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Refer to the Spark Plug Condition. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2075 Spark Plug: Testing and Inspection SPARK PLUG CONDITIONS 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. Gap growth will not average more than approximately 0.025 mm (0.001 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. Oil Or Ash Encrusted Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2076 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. 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. Scavenger Deposits Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but this is a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy, but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and can be cleaned using standard procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2077 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. 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.) Spark Plug Overheating Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2078 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2079 Spark Plug: Service and Repair Heat Shields On all engines, spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. PLUG REMOVAL Cable Removal 1. Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result. 2. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. This will help prevent foreign material from entering the combustion chamber. 3. Remove the spark plug using a quality socket with a rubber or foam insert. 4. Inspect the spark plug condition. Refer to Spark Plug Condition in the Diagnostics and Testing. PLUG CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. PLUG GAP ADJUSTMENT Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2080 Setting Spark Plug Gap - Typical Check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode. Never attempt to adjust the gap by bending the center electrode. SPARK PLUG GAP 1.01 mm (0.040 in) PLUG INSTALLATION Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 35-41 Nm (26-30 ft. lbs.) torque. 3. Install spark plug cables over spark plugs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression should not be less than 689 kPa (100 psi) and not vary more than 172 kPa (25 psi) from cylinder to cylinder. If cylinder(s) have abnormally low compression pressures, repeat procedure. - If the same cylinder(s) repeat an abnormally low reading, it could indicate the existence of a problem in the cylinder. NOTE: The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should NOT be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2084 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST 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. (Refer to Powertrain Management for the correct procedure) 5. Disconnect the ignition coil. 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. Refer to Engine Specifications for the correct engine compression pressures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all times. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation A/C Signal: Description and Operation AIR CONDITIONING (A/C) CONTROLS-PCM INPUT The A/C control system information applies to factory installed air conditioning units. A/C SELECT SIGNAL: When the A/C switch is in the ON position, an input signal is sent to the Powertrain Control Module (PCM). The signal informs the PCM that the A/C has been selected. The PCM adjusts idle speed to a pre-programmed rpm through the idle air control (IAC) motor to compensate for increased engine load. A/C REQUEST SIGNAL: Once A/C has been selected, the Powertrain Control Module (PCM) receives the A/C request signal from the clutch cycling pressure switch. The input indicates that the evaporator pressure is in the proper range for A/C application. The PCM uses this input to cycle the A/C compressor clutch (through the A/C relay). It will also determine the correct engine idle speed through the idle air control (IAC) motor position. If the A/C low-pressure switch or high-pressure switch opens (indicating a low or high refrigerant pressure), the PCM will not receive an A/C request signal. The PCM Will then remove the ground from the A/C relay This will deactivate the A/C compressor clutch. If the switch opens, (indicating that evaporator is not in proper pressure range), the PCM will not receive the A/C request signal. The PCM will then remove the ground from the A/C relay, deactivating the A/C compressor clutch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Intake Manifold Air Temperature Sensor 28 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2095 Intake Air Temperature Sensor: Locations Intake Manifold Air Temperature Sensor-Typical Intake Air Temperature Sensor, Engine Coolant Temperature Sensor Connector, Ignition Coil The intake manifold air temperature sensor is located in the front/side of the intake manifold. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2096 Intake Air Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2097 Intake Air Temperature Sensor: Description and Operation Intake Manifold Air Temperature Sensor INTAKE MANIFOLD AIR TEMPERATURE SENSOR-PCM INPUT The intake manifold air temperature sensor is installed in the intake manifold with the sensor element extending into the air stream. The sensor provides an input voltage to the Powertrain Control Module (PCM) indicating intake manifold air temperature. The input is used along with inputs from other sensors to determine injector pulse width. As the temperature of the air-fuel stream in the manifold varies, the sensor resistance changes. This results in a different input voltage to the PCM. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2098 Intake Air Temperature Sensor: Testing and Inspection To perform a complete test of the intake manifold air temperature sensor and its circuitry, refer to DRB tester and appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: Intake Manifold Air Temperature Sensor 1. Disconnect the wire harness connector from the intake manifold air temperature sensor. Sensor Resistance(Ohms)-Coolant Temperature Sensor/Intake Air Temperature Sensor 2. Test the resistance of the sensor with an input impedance (digital) volt-ohmmeter. The resistance (as measured across the sensor terminals) should be as shown in the previous SENSOR RESISTANCE (OHMS-COOLANT TEMPERATURE SENSOR/INTAKE AIR TEMPERATURE SENSOR chart. Replace the sensor if it is not within the range of resistance specified in the chart. 3. Test the resistance of the wire harness. Do this between the PCM wire harness connector A-15 and the sensor connector terminal. Also check between PCM connector A-4 to the sensor connector terminal. Repair the wire harness as necessary if the resistance is greater than 1 ohm. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2099 Intake Air Temperature Sensor: Service and Repair Intake Manifold Air Temperature Sensor-Typical The intake manifold air temperature sensor is located in the front/side of the intake manifold. REMOVAL 1. Remove air duct at throttle body. 2. Disconnect electrical connector at sensor 3. Remove sensor from intake manifold. INSTALLATION 1. Install sensor to intake manifold. Tighten to 28 Nm (20 ft. lbs.) torque. 2. Install electrical connector. 3. Install air duct at throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Battery Temperature Sensor The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2103 Battery Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2104 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2105 Battery Temperature Sensor: Description and Operation DESCRIPTION The battery temperature sensor is attached to the battery tray located under the battery. OPERATION The battery temperature sensor 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. BATTERY TEMPERATURE SENSOR-PCM INPUT Provides a signal to the PCM corresponding to the battery temperature. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor 1. The sensor is located on the front of the battery tray. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25° C (75-80° F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 2108 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. REMOVAL 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Locations Central Timer Module: Locations Module Locations CENTRAL TIMER MODULE The Durango utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The Base CTM does not communicate on the CCD bus and will not be addressed. The CTM performs most of the typical functions a Body Control Module would perform. The module is located on the right side of the glove box behind a metal bracket. It contains a white 18-way and a green 14-way connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN WHILE IN MOTION. DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 2114 Central Timer Module: 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Central Timer Module Central Timer Module: Description and Operation Central Timer Module DESCRIPTION Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the highline models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD 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. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. For diagnosis of the base version of the CTM, refer to Central Timer Module in the Diagnosis and Testing - Chime/Buzzer Warning Systems. For diagnosis of the high-line version of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-afterwash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermittent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. Refer to Central Timer module/Service and Repair of Instrument Panel Systems for the service procedures. See Wiper System Diagnosis and Testing for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. 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 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 Chrysler Collision Detection (CCD) 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. Refer to Remote Radio Switch in the Description and Operation for more information on this component. In addition, radio receivers connected to the CCD 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. The high-line CTM controls features and functions of the power lock, illuminated entry, and Remote Keyless Entry (RKE) systems. The high-line CTM receives hard wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio frequency inputs from the RKE transmitters. In response to those and many other inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the headlamp and horn relays, and the courtesy lamps. Some of the features and functions of the power lock, illuminated entry and RKE systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch when the driver door is open if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually, with a key, or energized with the RKE transmitter. - A programmable driver door unlock feature. The driver door unlock feature allows one press of the RKE transmitter Unlock button to unlock Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Central Timer Module > Page 2117 just the driver door, and a second press within five seconds to unlock all doors and the liftgate. If disabled, one press of the RKE transmitter Unlock button willunlock all doors and the liftgate. - A panic mode feature which can provide additional personal security and protection. When the Panic button on the RKE transmitter is depressed the vehicle horn will pulse, the headlights will flash, and the interior lights will illuminate on the vehicle for about three minutes, or until the Panic button is depressed a second time. A vehicle speed of about 24 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. - An enhanced accident response feature will unlock all doors and the liftgate, then prevent thepower door lock system from locking the doors and liftgate for a predetermined time interval, after receiving a CCD message from the ACM indicating a frontal impact of the vehicle requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates that the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors and the liftgate after the vehicle reaches a speed of about 24 kilometers-per-hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again, at any speed above 24 kilometers-per-hour (15 miles-per-hour). - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following activation of the RKE Lock function. This feature can be enabled or disabled and, if enabled, the horn chirp duration (twenty or forty milliseconds) can be selected. - Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the service procedures. - The programmable features of the CTM can be enabled or disabled using the DRB scan tool as described in the proper Diagnostic Procedures. These features can also be enabled/disabled using the customer programmable feature. See the owner's manual in the vehicle glove box for more information on the customer programmable feature. Refer to Central Timer Module in the Diagnosis and Testing for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. - One of the features that the high-line CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard- wired inputs from the door and liftgate ajar, door and liftgate lock cylinder, and ignition switches. The programming in the CTM allows it to process the information from these inputs and send control outputs to energize or de-energize the headlamp (or security) relay, horn relay, and the security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS - The high-line CTM also contains the receiver and control logic for the power lock and Remote Keyless Entry (RKE) systems, which are integrated into the arming, disarming, and triggering functions of the VTSS. - Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the service procedures. - For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. - One of the functions and features that both versions of the CTM support is the chime warning system. The CTM contains a chime tone generator to perform the functions of the chime warning module. The CTM uses hard-wired switch inputs, internal programming, and a hard-wired chime request input from the instrument cluster circuitry to detect when a chime tone is required. This covers the diagnosis and service of only the hard-wired inputs used by the CTM to determine that a chime tone should be generated. See Central Timer Module Diagnosis and Testing for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. OPERATION Some of the functions and features that the CTM supports or controls include: Chimes for the following conditions: - Headlamps on with ignition off and driver door open warning - Key in ignition with ignition off and driver door open warning - ABS lamp warning (if the vehicle is so equipped) - Airbag lamp warning - Check gauges lamp warning - Door ajar lamp warning - Low fuel lamp warning - Low washer fluid lamp warning - Seat belt reminder lamp warning Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Central Timer Module > Page 2118 - Transmission oil temperature lamp warning (automatic transmission) - Courtesy lamp defeat - Courtesy lamp time-out (high-line only) - Intermittent wipe control - Enhanced accident response (high-line only) - Horn chirp upon door lock with RKE (customer programmable) (high-line only) - Illuminated entry (high-line only) - Power door lock control (high-line only) - Power lock inhibit (high-line only) - Remote Keyless Entry (RKE) (high-line only) - Remote radio switches (high-line only) - Rolling door locks (customer programmable) (high-line only) - Speed sensitive intermittent wipe (high-line only) - Vehicle Theft Security System (VTSS) (high-line only) (if the vehicle is so equipped) - Wipe after wash (high-line only). More information on the operation of these CTM features and functions can be found in the system to which that feature or function applies. CENTRAL TIMER MODULE The Durango utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The Base CTM does not communicate on the CCD bus and will not be addressed. The CTM performs most of the typical functions a Body Control Module would perform. The Highline CTM provides the following features: Remote Keyless Entry (RKE) - Chime - Courtesy Lamp controls/Illuminated Entry - Power Door Locks - Speed Sensitive Intermittent Wipers - Enhanced Accident Response - Vehicle Theft Security System (VTSS) The module is located on the right side of the glove box behind a metal bracket. It contains a white 18-way and a green 14-way connector. Central Timer Module Diagnostic Trouble Codes - Door Disarm Switch Failure - Door Lock Switch Failure - Door Unlock Switch Failure - Wiper Park Switch Failure - EEPROM Checksum Failure - Internal ROM Test Failure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Central Timer Module > Page 2119 Central Timer Module: Description and Operation DRB III Error Messages and Blank Screen DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB will display one of only two error messages: User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, recored the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key itf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III Does Not Power Up (blank Screen) 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. Perform the "DRB Blank Screen" test under Vehicle Communication. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Information Bus/DRB Blank Screen DRB III Display Is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Central Timer Module > Page 2120 Central Timer Module: Description and Operation General Information Module Locations SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 1999 Durango consists of five modules that communicate over the CCD bus (Chrysler Collision Detection multiplex system). There are two additional modules, the Powertrain Control Module (PCM) and the Controller Anti-Lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication, The CAB also utilizes the bus for diagnostics. The PCM sends and receives messages on the CCD bus, however diagnostics are performed through the Serial Communication Interface (SCI), the same as previous years. All of the information about the functioning of all the systems is organized, controlled, and communicated by the CCD bus, which is described in Vehicle Communication. Through the CCD 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 the information to perform it's 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. 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 CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Mechanical Instrument Cluster (MIC) from the ACM via the CCD 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. Perform the WARNING LAMP CIRCUIT OPEN procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: warning lamp does not illuminate - warning lamp stays illuminated 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Central Timer Module > Page 2121 AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. CENTRAL TIMER MODULE The Durango utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The Base CTM does not communicate on the CCD bus and will not be addressed. The CTM performs most of the typical functions a Body Control Module would perform. The Highline CTM provides the following features: Remote Keyless Entry (RKE) - Chime - Courtesy Lamp controls/Illuminated Entry - Power Door Locks - Speed Sensitive Intermittent Wipers - Enhanced Accident Response - Vehicle Theft Security System (VTSS) The module is located on the right side of the glove box behind a metal bracket. It contains a white 18-way and a green 14-way connector. Chime system The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for seat belt, gauge problems and tell-tale warnings. There are two chime rates, Low; 50 ± 12 chimes per minute for reminders and High; 180 ± 12 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 doors are open or the headlights 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 approximately 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 - Seat belt warning - Check engine lamp illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Anti-lock lamp illuminated (after prove-out if equipped) - Check gauges lamp illuminated - Low fuel warning lamp illuminated - Low washer fluid - Door ajar 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/100Km since the last reset. Instantaneous Fuel Economy Shows the fuel economy for the last few seconds in MPG or L/100Km. 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 minitrip computer displays. US/M Button Press this button to convert all vehicle displays from US to Metric to US. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Central Timer Module > Page 2122 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, Trip Odometer, ET) is currently being displayed. 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. Enhanced Accident Response (Highline CTM Only) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the CCD bus to the CTM module to unlock the doors. The interior lights will be turned ON when the vehicle speed message on the CCD 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. Interior Lighting The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The highline CTM also provides for illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door disarm switch input or the door jamb switch input, the interior courtesy lights will be turned ON. The illuminated entry function is canceled if the CTM senses an ignition "ON" condition or the "lock" command from a valid key fob. If a door is left open or turned ON by rotation of dimmer switch for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned ON by courtesy lamp switch, the CTM will not be able to turn them OFF. The Durango utilizes an interior light defeat switch as an integral part of the headlamp switch. Mechanical Instrument Cluster (MIC) The MIC is available in 4 different versions. Two of the versions are Canadian clusters. There is a highline and a low line cluster available. The difference is the addition of a tachometer in the highline. In order to accomplish this, the fuel level gauge is reduced in size and oil pressure gauge is relocated. The cluster positions its gauges with bus messages received from the PCM. The odometer is a Liquid Crystal Display (LCD). The cluster will provide bus bias and the PCM provides termination. The MIC has an internal diagnostic routing that can be accessed by pushing and holding the trip odometer while rotating the key to the ON position. The cluster will then place all the gauges at their calibration points and will light all the CCD driven tell-tales. It will also light all the segments of the LCD display for a visual verification check. The MIC can verify communications with the PCM, ID the module, or change the country code by using options 1, 3, or 9 on the DRB III under the MIC menu. If there are faults found during the diagnostic routine, the cluster will report them on the LCD odometer display. Power Door Locks The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is OFF, the door is open, and the key is in the ignition. Automatic or "rolling locks" are included as a DRB III, or customer 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 CCD bus) indicating acceleration, the CTM will cycle the lock actuators to lock the doors. RKE/VTSS If the vehicle is equipped with Remote Keyless Entry (RKE), programming of additional transmitters and horn chirp are customer programmable features, The highline CTM provides for RKE and the Vehicle Theft Security System (VTSS). The base CTM is not able to provide these functions. The presence of either of these options dictates that the vehicle is equipped with a highline CTM. The VTSS system monitors the door ajar switches, liftgate 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, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes. After 15 minutes 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Central Timer Module > Page 2123 DRB III. The system may be disarmed by either an unlock command from a valid RKE key fob or by using a key in the lift gate or either door. Both front door key cylinders and the lift gate 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. The RKE system is placed in the programming mode by the DRB, or by using the customer programming sequence. The system will store up to four key fob codes. Two fobs are supplied with the truck, additional fobs may be purchased through parts department. The additional fobs can be programmed with the DRB III, or by using the customer programming sequence. 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. Speed Sensitive Intermittent Wipers The DN truck equipped with a highine CTM will utilize speed sensitive intermittent wipers. Only a highine CTM Will be able to support this feature. A base CTM will provide for intermittent wipers without the speed sensitive feature. 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. Diagnostics The CTM is fully addressable with the DRB III and it is the recommended method for diagnosis. The CTM reports 6 Diagnostic Trouble Codes. All of the inputs to the CTM can be read with the DRB and the outputs can be actuated. VEHICLE COMMUNICATION The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, and is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measureable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network" located in the module that supplies bus bias or voltage. Along with the module that supplies bias, some modules provide termination. Bias is the voltage necessary to make the bus operational. At least one point of termination is necessary, some systems may use more than one. Some modules are capable of both biasing and terminating. Termination in the circuitry (a 120 ohm resistor placed across the bus) is required to complete the voltage divider network circuit and also provide some electromagnetic protection for the bus. In this vehicle, the bias is supplied by the instrument cluster and termination is provided by the PCM and the instrument cluster. Without termination, voltage on the bus goes to approximately 5 volts on one wire and 0 volts on the other wire. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB III. Problems with the operation of the bus or DRB III must corrected before proceeding with diagnostic testing. Bus Failure Messages Short to Battery - Either or both of the bus wires are shorted to the battery potential, or Open ground to any CCD bus module. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of the bus wires are shorted to ground. Bus (+) L Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with the Instrument Cluster. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Central Timer Module > Page 2124 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. The procedure begins with AIRBAG TEST 1A-Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. 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 for 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 occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. 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 the 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, the 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. Airbag Diagnostic Trouble Codes The airbag control module may report any of the following diagnostic trouble codes. For the following codes, replace the Airbag Control Module (ACM) even if set intermittently: ACM Accelerometer - Internal Diagnostic 1 - Internal Diagnostic 2 For the following codes, replace the Airbag Control Module (ACM): ACM Output Driver - ACM Stored Energy Logic - ACM Stored Energy Driver - ACM Stored Energy Passenger - Internal Diagnostic 3 - Internal Diagnostic 4 - Safing Sensor Shorted - Warning Lamp Driver Error For these codes, refer to the appropriate diagnostic procedure: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Central Timer Module > Page 2125 - Driver Squib Open - Driver Squib Shorted - Loss of Ignition Run Only - Loss of Ignition Run/Start - No CCD Communication - Passenger Squib Circuit Open - Passenger Squib Circuit Shorted - Either Squib Terminal Short to Battery - Either Squib Terminal Short to Ground - Warning Lamp Circuit Open - Warning Circuit Shorted Central Timer Module Diagnostic Trouble Codes - Door Disarm Switch Failure - Door Lock Switch Failure - Door Unlock Switch Failure - Wiper Park Switch Failure - EEPROM Checksum Failure - Internal ROM Test Failure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 AM/FM Switch Inoperative SYMPTOM AM-FM SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Balance Dial Inoperative SYMPTOM BALANCE DIAL INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative CD Eject Switch Inoperative SYMPTOM CD EJECT SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Equalizer Inoperative SYMPTOM EQUALIZER INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative External CD Changer (If Equipped) SYMPTOM * EXTERNAL CD CHANGER (IF EQUIPPED) POSSIBLE CAUSES - CD cable assembly defective - CD changer defective - Defective radio Fader Dial Inoperative SYMPTOM FADER DIAL INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative FF/RW Switch Inoperative SYMPTOM Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2128 FF/RW SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Hour/Minute Switch Inoperative SYMPTOM HOUR/MINUTE SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative No Sound From All Speakers SYMPTOM * NO SOUND FROM ALL SPEAKERS POSSIBLE CAUSES - Radio 12 V output circuit defective - Radio defective - Radio defective - Fused B(+) circuit open - Ground circuit open - Defective radio No Sound From One Speaker SYMPTOM * NO SOUND FROM ONE SPEAKER POSSIBLE CAUSES - Pillar speaker (+) circuit open - Pillar speaker (-) circuit open - Pillar speaker defective - Speaker (-) circuit shorted - Speaker defective - Amplifier speaker (+) circuit open - Amplifier speaker (-) circuit open - Power amplifier defective - Power amplifier defective Pause/Play Switch Inoperative SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Poor Sound Quality All Speakers SYMPTOM * POOR SOUND QUALITY ALL SPEAKERS POSSIBLE CAUSES - Antenna connector connection defective - Radio 12 V output circuit defective - Radio connections defective - Radio defective Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2129 - Radio defective - Fused B(+) circuit open - Ground circuit open - Radio choke relay connection defective Poor Sound Quality From One Speaker SYMPTOM * POOR SOUND QUALITY FROM ONE SPEAKER POSSIBLE CAUSES - Pillar/lower speaker (+) circuit open - Pillar lower speaker (-) circuit open - Pillar speaker defective - Radio defective - Radio defective - Speaker (+) circuit open - Speaker (-) circuit open - Speaker defective PWR Switch Inoperative SYMPTOM PWR SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Remote Steering Wheel Switches (If Equipped) SYMPTOM * REMOTE STEERING WHEEL SWITCHES (IF EQUIPPED) POSSIBLE CAUSES - MUX control clockspring defective - Radio control circuit defective open - Radio control switch ground circuit open - Radio MUX control circuit defective - Remote control switch defective - No response CCD bus failure - Radio control MUX circuit open - Central timer module defective Scan Switch Inoperative SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Seek Switch Inoperative SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2130 Set Switch Inoperative SYMPTOM SET SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Shorted Front Channel SYMPTOM SHORTED FRONT CHANNEL POSSIBLE CAUSES - Radio defective - Right front SPKR (+) circuit short to ground - Right front SPKR (-) circuit short to ground - Left front SPKR (+) circuit short to ground - Left front SPKR (-) circuit short to ground Shorted Left Channel SYMPTOM SHORTED LEFT CHANNEL POSSIBLE CAUSES - Left rear SPKR (+) circuit short to ground - Left rear SPKR (-) circuit short to ground - Left front SPKR (+) circuit short to ground - Left front SPKR (-) circuit short to ground - Radio defective Shorted Rear Channel SYMPTOM SHORTED REAR CHANNEL POSSIBLE CAUSES - Left rear SPKR (+) circuit short to ground - Left rear SPKR (-) circuit short to ground - Radio defective - Right rear SPKR (+) circuit short to ground - Right rear SPKR (-) circuit short to ground Shorted Right Channel SYMPTOM SHORTED RIGHT CHANNEL POSSIBLE CAUSES - Right rear SPKR (+) circuit short to ground - Right rear SPKR (-) circuit short to ground - Right front SPKR (+) circuit short to ground - Radio defective - Right front SPKR (-) circuit short to ground Tape Eject Switch Inoperative SYMPTOM TAPE EJECT SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2131 Tune Switch Inoperative SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Volume/Time Switch Inoperative SYMPTOM VOL/TIME SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative 1-5 Presets Inoperative SYMPTOM 1-5 PRESETS INOPERATIVE POSSIBLE CAUSES - Radio function controls inoperative Chime Inoperative - Engine Temperature Critical SYMPTOM * CHIME INOPERATIVE - ENGINE TEMPERATURE CRITICAL POSSIBLE CAUSES - Tone request circuit open - Instrument cluster tone request output defective - CTM fails chime test - PCM DTC - coolant temp check Chime Inoperative - Key In Ignition & LF Door Open SYMPTOM * CHIME INOPERATIVE - KEY IN IGNITION & LF DOOR OPEN POSSIBLE CAUSES - Key in ignition SW sense CKT open - Ignition SW-key in SW open - CTM no chime to key in ignition - CTM not responding to key in SW Chime Inoperative at All Times SYMPTOM * CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM fails internal chime test Chime Inoperative With Exterior Lamps On SYMPTOM * CHIME INOPERATIVE WITH EXTERIOR LAMPS ON POSSIBLE CAUSES - Headlamp switch circuit open Chime Inoperative With Low Oil Pressure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2132 SYMPTOM * CHIME INOPERATIVE WITH LOW OIL PRESSURE POSSIBLE CAUSES - Oil pressure sender ground circuit open - Tone request circuit open - Instrument cluster - oil press defective - CTM no response to oil pressure default - CTM fails chime test Chime Sounds With Driver Door Open SYMPTOM * CHIME SOUNDS WITH DRIVER DOOR OPEN POSSIBLE CAUSES - Key in ignition switch sense circuit short to ground - Ignition SW - key in SW shorted - CTM - key in sense short default - CTM not responding to key out Open Driver Door Ajar Circuit SYMPTOM * OPEN DRIVER DOOR AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Left front ajar switch sense circuit open - Left front door ajar switch defective shorted - Left front door ajar switch sense circuit open Open Gate Ajar Circuit SYMPTOM * OPEN GATE AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Liftgate ajar switch sense circuit defective open - Liftgate door ajar ground circuit defective open - Liftgate door ajar switch defective open Open Left Rear Door Ajar Circuit SYMPTOM * OPEN LEFT REAR DOOR AJAR CIRCUIT POSSIBLE CAUSES - Left rear door ajar switch sense circuit defective open - CTM defective - Ground circuit defective open - Left rear door ajar switch defective open Open Right Front Door Ajar Circuit SYMPTOM * OPEN RIGHT FRONT DOOR AJAR CIRCUIT POSSIBLE CAUSES - RF door ajar switch sense (ground circuit) open - Right front door ajar switch sense circuit open - CTM defective - Right front door ajar switch defective open Open Right Rear Door Ajar Circuit SYMPTOM * OPEN RIGHT REAR DOOR AJAR CIRCUIT Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2133 POSSIBLE CAUSES - Right rear door ajar switch sense circuit defective open - CTM defective - Ground circuit defective open - Right rear door ajar switch defective open Shorted Driver Door Ajar Circuit SYMPTOM * SHORTED DRIVER DOOR AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Left front door ajar switch defective shorted - LF door ajar switch sense circuit short to GND Shorted Gate Ajar Circuit SYMPTOM * SHORTED GATE AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Liftgate ajar switch defective shorted - Liftgate ajar switch sense circuit defective short to GND Shorted Passenger Door Ajar Circuit SYMPTOM * SHORTED PASSENGER DOOR AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Door ajar switch sense circuit short to ground - Right front door ajar switch defective shorted - Right rear door ajar switch DEF shorted - Left rear door ajar switch DEF shorted All Gauges Inoperative SYMPTOM * ALL GAUGES INOPERATIVE POSSIBLE CAUSES - No response/CCD bus (MIC) - Fuse #17 open - Fused ignition switch output circuit open - Instrument cluster defective Any CCD Cluster Warning Lamp Inoperative SYMPTOM * ANY CCD CLUSTER LAMP INOPERATIVE POSSIBLE CAUSES - No response/CCD bus (MIC) - CCD inoperative lamp/bulb defective - CCD lamp cluster input defective - Defective cluster - CCD LP cluster test complete Any Hard Wired Cluster Warning Lamp SYMPTOM * ANY HARD WIRED LAMP INOPERATIVE POSSIBLE CAUSES - Hard wired lamp circuit open Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2134 - Inoperative lamp/bulb defective - Defective instrument cluster One Gauge Not Operating Properly SYMPTOM * ONE GAUGE NOT OPERATING PROPERLY POSSIBLE CAUSES - Gauge not reading 4 PSI> engine warm at idle - Oil gauge not reading 4 PSI Or > at idle - Oil level low - Instrument cluster circuit board defective - Oil pressure sensor defective - Instrument cluster defective - Oil pressure sense circuit open - Oil pressure sense signal CKT short to ground - Cooling system operation faulty - DRB shows ECT sensor voltage too high - DRB shows ECT sensor voltage too low - Check for PCM DTC'S - Defective JTEC module - Fuel gauge inoperative - JTEC module defective - Oil pressure switch defective - Pinion factor incorrect - Powertrain control module defective - Tachometer inoperative - Voltage gauge inoperative Average MPH/Fuel Econ Inoperative or Wrong SYMPTOM * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG POSSIBLE CAUSES - Defective compass/mini-trip computer CMTC Display Shows Failed SYMPTOM * CMTC DISPLAY SHOWS FAILED POSSIBLE CAUSES - Defective CMTC display failed CMTC Fails to Respond to Instrument Panel Dimming SYMPTOM * CMTC FAILS TO RESPOND TO INSTRUMENT PANEL DIMMING TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer CMTC Segments Fail to Light Up SYMPTOM * CMTC SEGMENTS FAIL TO LIGHT UP POSSIBLE CAUSES - Defective compass mini-trip computer-segments fail to light Distance to Empty Inoperative or Wrong SYMPTOM * DISTANCE TO EMPTY INOPERATIVE OR WRONG Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2135 TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer Elapsed Time Inoperative/Wrong SYMPTOM * ELAPSED TIME INOPERATIVE/WRONG TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer Repairing OC In CMTC Display SYMPTOM * REPAIRING "OC" IN CMTC DISPLAY POSSIBLE CAUSES - Open sensor ground circuit - Defective ambient temperature sensor-SC - Open ambient temperature sensor signal circuit - Defective CMTM/OC default Repairing SC In CMTC Display SYMPTOM * REPAIRING "OC" IN CMTC DISPLAY POSSIBLE CAUSES - Ambient temperature sensor signal CKT-SH/sensor GND - Defective ambient temperature sensor-OC - Ambient temperature sensor signal CKT-short/GND - Defective CMTM/SC default Switch on Compass Mini-Trip Computer Inoperative SYMPTOM * SWITCH ON COMPASS MINI-TRIP COMPUTER INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer Trip Odometer Inoperative/Wrong SYMPTOM * TRIP ODOMETER INOPERATIVE/WRONG TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer Automatic (Rolling) Door Locks Inoperative SYMPTOM * AUTOMATIC (ROLLING) DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Link to body communication bus inoperative Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2136 - Speed sensing door locks inoperative Doors Lock With Key In Ignition and Left Door Open SYMPTOM * DOORS LOCK WITH KEY IN IGNITION AND LEFT DOOR OPEN POSSIBLE CAUSES - Link to body communication bus inoperative - Ignition switch shorted - Key-in ignition switch sense circuit open - CTM input A9 short to ground - CTM input shorted to ground One or All Doors Failing to Lock From One Switch SYMPTOM * ONE OR ALL DOORS FAILING TO LOCK FROM ONE SWITCH POSSIBLE CAUSES - Link to body communication bus inoperative - Door lock actuator assembly defective - Door unlock actuator assembly defective - Door lock switch assembly open - Door unlock switch assembly open - Door lock driver circuit open - Fused B (+) circuit open - Door lock driver circuit open - Power door lock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - CTM lock driver input open - CTM unlock driver input open - Lock driver circuit on CTM open - Unlock driver circuit on CTM open One or All Doors Failing to Unlock From One Switch SYMPTOM * ONE OR ALL DOORS FAILING TO UNLOCK FROM ONE SWITCH TEST NOTE: This symptom is diagnosed using the test * ONE OR ALL DOORS FAILING TO LOCK FROM ONE SWITCH. POSSIBLE CAUSES - Link to body communication bus inoperative - Door lock actuator assembly defective - Door unlock actuator assembly defective - Door lock switch assembly open - Door unlock switch assembly open - Door lock driver circuit open - Fused B (+) circuit open - Door lock driver circuit open - Power door lock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - CTM lock driver input open - CTM unlock driver input open - Lock driver circuit on CTM open - Unlock driver circuit on CTM open Remote Keyless Entry Problem SYMPTOM * REMOTE KEYLESS ENTRY PROBLEM POSSIBLE CAUSES - Link to body communication bus inoperative Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2137 - Transmitter defective - Circuit between CTM & left front UNLCK RLY open - Door unlock relay defective - Door unlock relay internal defect - Left front door unlock relay coil out of tolerance - Left front door unlock relay B (+) circuit open - Unlock relay B (+) circuit open (CAV 87) - CTM defective-RKE function - CTM unlock relay signal inoperative - Left front door unlock relay circuit at CTM open Intermittent Wipers Inoperative SYMPTOM * INTERMITTENT WIPERS INOPERATIVE POSSIBLE CAUSES - No response/CCD bus failure - CTM - Open intermittent wiper mode sense CKT - Open wiper park switch sense CKT - Defective wiper motor/12 volts - Defective CTM/12 volt default - Defective CTM/STALK switch - Defective multi-function switch/5.0 ohms No Wipe After Washers Actuated SYMPTOM * NO WIPE AFTER WASHERS ACTUATED POSSIBLE CAUSES - CCD bus failure-no response CTM - Open front washer switch sensor CKT - Defective CTM/washer pump Wiper Speed Sensitive Feature Inoperative SYMPTOM * WIPER SPEED SENSITIVE FEATURE INOPERATIVE POSSIBLE CAUSES - CCD bus failure-CTM - CCD bus failure PCM - Defective CTM/wiper intervals Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2138 Central Timer Module: Component Tests and General Diagnostics 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 SCREEN WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2139 Central Timer Module: Scan Tool Testing and Procedures Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, recored the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key itf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III Does Not Power Up (blank Screen) 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. Perform the "DRB Blank Screen" test under Vehicle Communication. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Information Bus/DRB Blank Screen DRB III Display Is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 2140 Central Timer Module: Tools and Equipment DRB III (Diagnostic Read Out Box) Jumper Wires Ohmmeter Voltmeter Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor Oil Pressure Sending Unit/Switch, Camshaft Position Sensor Connector The camshaft position sensor is located in the distributor on all engines. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2144 Camshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2145 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor CAMSHAFT POSITION SENSOR - PCM INPUT A sync signal is provide by the camshaft position sensor located in the distributor. The sync signal from this sensor works in conjunction with the crankshaft position sensor to provide the Powertrain Control Module (PCM) with inputs. This is done to establish and maintain correct injector firing order. CAMSHAFT POSITION SENSOR The camshaft position sensor is located in the distributor on all engines. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2146 Camshaft Position Sensor: Testing and Inspection Camshaft Position Sensor The camshaft position sensor is located in the distributor on all engines. To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: For this test, an analog (non-digital) voltmeter is needed. Do not remove the distributor connector from the distributor. Using small paper clips, insert them into the backside of the distributor wire harness connector to make contact with the terminals. Be sure that the connector is not damaged when inserting the paper clips. Attach voltmeter leads to these paper clips. 1. Connect the positive (+) voltmeter lead into the sensor output wire. This is at done the distributor wire harness connector. 2. Connect the negative (-) voltmeter lead into the ground wire. 3. Set the voltmeter to the 15 Volt DC scale. 4. Remove distributor cap from distributor (two screws). Rotate (crank) the engine until the distributor rotor is pointed towards the rear of vehicle. The movable pulse ring should now be within the sensor pickup. 5. Turn ignition key to ON position. Voltmeter should read approximately 5.0 volts. 6. If voltage is not present, check the voltmeter leads for a good connection. 7. If voltage is still not present, check for voltage at the supply wire. For wire identification, refer to Wiring Diagrams. 8. If 5 volts is not present at supply wire, check for voltage at PCM 32-way connector (cavity A-17). Leave the PCM connector connected for this test. 9. If voltage is still not present, perform vehicle test using the DRB scan tool. 10. If voltage is present at cavity A-17, but not at the supply wire: a. Check continuity between the supply wire. This is checked between the distributor connector and cavity A-17 at the PCM. If continuity is not present, repair the harness as necessary. b. Check for continuity between the camshaft position sensor output wire and cavity A-18 at the PCM, If continuity is not present, repair the harness as necessary. c. Check for continuity between the ground circuit wire at the distributor connector and ground. If continuity is not present, repair the harness as necessary. 11. While observing the voltmeter, crank the engine with ignition switch. The voltmeter needle should fluctuate between 0 and 5 volts while the engine is cranking. This verifies that the camshaft position sensor in the distributor is operating properly and a sync pulse signal is being generated. If sync pulse signal is not present, replacement of the camshaft position sensor is necessary Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2147 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor The camshaft position sensor is located in the distributor on all engines. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove air cleaner assembly. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. tighten mounting screws. 5. Install air cleaner assembly. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 11 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2151 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor-Typical Intake Air Temperature Sensor, Engine Coolant Temperature Sensor Connector, Ignition Coil The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2152 Engine Coolant Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2153 Coolant Temperature Sensor/Switch (For Computer): Service Precautions WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2154 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT The engine coolant temperature sensor is installed into a water jacket at the front of the intake manifold located near the rear of the generator. The sensor provides an input voltage to the Powertrain Control Module (PCM) relating coolant temperature. The PCM uses this input along with inputs from other sensors to determine injector pulse width and ignition timing. As coolant temperature varies, the coolant temperature sensor resistance will change. This change in resistance results in a different input voltage to the PCM. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2155 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: Engine Coolant Temperature Sensor-Typical 1. Disconnect wire harness connector from coolant temperature sensor. 2. Engines with air conditioning: When removing the connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place the hook part of tool under the connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. Sensor Resistance(Ohms)-Coolant Temperature Sensor/Intake Air Temperature Sensor 3. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. The resistance (as measured across the sensor terminals) should be as shown in the SENSOR RESISTANCE (OHMS)-COOLANT TEMPERATURE SENSOR/INTAKE AIR TEMPERATURE SENSOR resistance chart. Replace the sensor if it is not within the range of resistance specified in the chart. 4. Test continuity of the wire harness between the PCM wire harness connector and the coolant sensor connector terminals. Refer to Wiring for terminal/cavity locations. Repair the wire harness if an open circuit is indicated. 5. After tests are completed, connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2156 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor-Typical The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain cooling system. 2. Disconnect electrical connector from sensor. 3. Engines with air conditioning: When removing the connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place the hook part of tool under the connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Use long needle nose pliers to connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. 4. Replace any lost engine coolant. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor 8 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2160 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The sensor is bolted to the cylinder block near the rear of the right cylinder head. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2161 Crankshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2162 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR 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. Sensor Operation The flywheel/drive plate has 8 single notches, spaced every 45 degrees, 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. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a crankshaft position sensor input. CRANKSHAFT POSITION SENSOR-PCM INPUT This sensor is a hall effect device that detects notches in the flywheel (manual transmission) or flexplate (automatic transmission). This sensor is used to indicate to the Powertrain Control Module (PCM) that a spark and or fuel injection event is to be required. The output from this sensor, in conjunction with the camshaft position sensor signal, is used to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2163 Crankshaft Position Sensor The sensor is bolted to the cylinder block near the rear of the right cylinder head. Refer to Ignition System for more crankshaft position sensor information. The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2164 Crankshaft Position Sensor: Testing and Inspection To perform a complete test of this sensor and its circuitry, refer to the DRB scan tool. Also refer to the appropriate Powertrain Diagnostics Procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2165 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. 1. Remove right front tire and right front wheelhouse liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheelhouse liner. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations Data Link Connector (DLC) Data Link Connector Data Link Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2171 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2172 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2173 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2174 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2175 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2176 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2177 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2178 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2179 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2180 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2181 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2182 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2183 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2184 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2185 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2186 Data Link Connector: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2187 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2188 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2189 Data Link Connector: Connector Views Connector Pin Identification Data Link Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 2190 Data Link Connector: Description and Operation Data Link Connector Location DATA LINK CONNECTOR-PCM INPUT AND OUTPUT 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). The data link connector is located under the instrument panel to the left of the steering column. For operation of the DRB scan tool, refer to the appropriate Powertrain Diagnostic Procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Specifications Powertrain Control Module: Specifications Powertrain Control Module Mounting Screws 1 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Specifications > Page 2194 Powertrain Control Module: Locations PCM Location And Mounting Powertrain Control Module The PCM is located in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2197 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2198 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2199 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2200 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2201 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2202 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2203 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2204 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2205 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2206 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2207 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2208 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2209 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2210 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2211 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2212 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2213 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2214 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2215 Powertrain Control Module: Connector Views Powertrain Control Module C1 Powertrain Control Module C2 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2216 Powertrain Control Module C3 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2217 Powertrain Control Module: Service and Repair PCM Location And Mounting The PCM is located in the engine compartment. REMOVAL 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 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. IMPORTANT NOTE: If the Powertrain Control Module has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the ABS and Air bag modules. In addition, if the vehicle is equipped with a Sentry Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. FOR ABS AND AIR BAG SYSTEMS: 1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS and Air Bag modules. FOR SKIM THEFT ALARM: 1. Connect the DRBIII to the data link connector. 2. Go to Theft Alarm, SKIM, Misc. and place the SKIM in secured access mode, by using the appropriate PIN code for this vehicle. 3. Select Update the Secret Key data, data will be transferred from the SKIM to the PCM (This is required to allow the vehicle to start with the new PCM). 4. If three attempts are made to enter secured access mode using the incorrect PIN, secured access mode will be locked out for one hour. To exit this lock out mode, leave the ignition key in the Run/Start position for one hour. Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR-PCM INPUT The Powertrain Control Module (PCM) supplies power to the fuel level sensor (fuel gauge sending unit). The fuel level sensor will then return a signal to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes. This is if the fuel level is less than approximately 15 percent, or, if equipped with a Leak Detection Pump (LDP), more than approximately 85 percent of its rated capacity. This input is also used to send a signal to the PCM for fuel gauge operation via the CCD bus circuits. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications IAC Motor-To-Throttle Body Bolts 7 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2224 Idle Speed/Throttle Actuator - Electronic: Locations Mounting Bolts(Screws)-IAC Motor MAP Sensor, Idle Air Control Motor, Throttle Position Sensor The IAC motor is mounted to the back of the throttle body Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2225 Idle Air Control Motor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2226 Idle Speed/Throttle Actuator - Electronic: Description and Operation Throttle Body Air Control Passage IDLE AIR CONTROL (IAC) MOTOR-PCM OUTPUT The IAC motor is mounted to the back of the throttle body and is controlled by the Powertrain Control Module (PCM). The throttle body has an air control passage that provides air for the engine at idle (the throttle plate is closed). The IAC motor pintle protrudes into the air control passage and regulates air flow through it. Based on various sensor inputs, the Powertrain Control Module (PCM) adjusts engine idle speed by moving the IAC motor pintle in and out of the air control passage. The IAC motor is positioned when the ignition key is turned to the On position. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2227 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection To perform a complete test of the IAC motor and its circuitry, refer to Computers and Control Systems/Testing and Inspection. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2228 Idle Speed/Throttle Actuator - Electronic: Service and Repair Mounting Bolts(Screws)-IAC Motor The IAC motor is located on the back of the throttle body. REMOVAL 1. Remove air duct at throttle body. 2. Disconnect electrical connector from 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 at throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2233 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2234 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2235 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2236 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2237 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2238 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2239 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2240 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2241 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2242 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2243 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2244 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2245 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2246 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2247 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2248 Information Bus: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2249 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2250 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2251 CCD Bus System Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2252 Information Bus: Description and Operation VEHICLE COMMUNICATION The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, and is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measureable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network" located in the module that supplies bus bias or voltage. Along with the module that supplies bias, some modules provide termination. Bias is the voltage necessary to make the bus operational. At least one point of termination is necessary, some systems may use more than one. Some modules are capable of both biasing and terminating. Termination in the circuitry (a 120 ohm resistor placed across the bus) is required to complete the voltage divider network circuit and also provide some electromagnetic protection for the bus. In this vehicle, the bias is supplied by the instrument cluster and termination is provided by the PCM and the instrument cluster. Without termination, voltage on the bus goes to approximately 5 volts on one wire and 0 volts on the other wire. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB III®. Problems with the operation of the bus or DRB III® must corrected before proceeding with diagnostic testing. Bus Failure Messages Short to Battery - Either or both of the bus wires are shorted to the battery potential, or open ground to any CCD bus module. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of the bus wires are shorted to ground. Bus (+) L Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with the Instrument Cluster. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Power Distributor Center (PDC) Location Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2256 Power Distribution Center The ASD relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2257 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down (ASD) Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2258 Automatic Shut Down (ASD) Relay: Description and Operation AUTOMATIC SHUTDOWN (ASD) RELAY SENSE-PCM INPUT Power Distribution Center(PDC) A 12 volt signal at this input indicates to the Powertrain Control Module (PCM) that the ASD has been activated. The ASD relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. 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 PCM does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). AUTO SHUTDOWN (ASD) RELAY-PCM OUTPUT The ASD relay is located in the Power Distribution Center (PDC). The ASD supplies battery voltage to the fuel injectors, ignition coil and oxygen (O2S) sensor heating elements. The ground circuit for the coil in the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the relay by switching the ground circuit on and off. AUTOMATIC SHUTDOWN (ASD) RELAY As one of its functions, the ASD relay will supply battery voltage to the ignition coil. The ground circuit for the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM regulates ASD relay operation by switching the ground circuit on-and-off. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2259 Automatic Shut Down (ASD) Relay: Testing and Inspection ASD And Fuel Pump Relay Terminals 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. Operation 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. Testing The following procedure applies to the ASD and fuel pump relays. 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 ± 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 source5 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2260 Automatic Shut Down (ASD) Relay: Service and Repair Power Distributor Center (PDC) Location The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. REMOVAL 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 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Application and ID Malfunction Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Check Engine Light ............................................................................................................................. .............................................................. PC194 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications MAP Sensor Mounting Screws 3 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2267 Manifold Pressure/Vacuum Sensor: Locations MAP And Throttle Position Sensor Location The MAP sensor is mounted on the side of the engine throttle body. The sensor is connected to the throttle body with a rubber L-shaped fitting. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2268 Manifold Absolute Pressure Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2269 Manifold Pressure/Vacuum Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR-PCM INPUT The MAP sensor reacts to absolute pressure in the intake manifold. It provides an input voltage to the Powertrain Control Module (PCM). As engine load changes, manifold pressure varies. The change in manifold pressure causes MAP sensor voltage to change. The change in MAP sensor voltage results in a different input voltage to the PCM. The input voltage level supplies the PCM with information about ambient barometric pressure during engine start-up (cranking) and engine load while the engine is running. The PCM uses this input along with inputs from other sensors to adjust air-fuel mixture. MAP And Throttle Position Sensor Location The MAP sensor is mounted on the side of the engine throttle body. The sensor is connected to the throttle body with a rubber L-shaped fitting. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2270 Manifold Pressure/Vacuum Sensor: Testing and Inspection MAP Sensor-Typical To perform a complete test of MAP sensor and its circuitry, refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the MAP sensor only, refer to the following: Rubber L-shaped Fitting-MAP Sensor-to-Throttle Body 1. Inspect the rubber L-shaped fitting from the MAP sensor to the throttle body. Repair as necessary. CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2271 MAP Sensor Connector Terminals-Typical 2. Test the MAP sensor output voltage at the MAP sensor connector between terminals A and B. With the ignition switch ON and the engine OFF, output voltage should be 4-to-5 volts. The voltage should drop to 1.5-to-2.1 volts with a hot, neutral idle speed condition. 3. Test Powertrain Control Module (PCM) cavity A-27 for the same voltage described above to verify the wire harness condition. Repair as necessary. 4. Test MAP sensor supply voltage at sensor connector between terminals A and C with the ignition ON. The voltage should be approximately 5 volts (± 0.5V). Five volts (± 0.5V) should also be at cavity A-17 of the PCM wire harness connector. Repair or replace the wire harness as necessary. 5. Test the MAP sensor ground circuit at sensor connector terminal-A and PCM connector A-4. Repair the wire harness if necessary Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2272 Manifold Pressure/Vacuum Sensor: Service and Repair MAP Sensor Location MAP Sensor L-Shaped Rubber Fitting The MAP sensor is located on the front of the throttle body. An L-shaped rubber fitting is used to connect the MAP sensor to throttle body. REMOVAL 1. Remove air duct at throttle body. 2. Remove two MAP sensor mounting bolts (screws). 3. While removing MAP sensor, slide the vacuum rubber L-shaped fitting from the throttle body. 4. Remove rubber L-shaped fitting from MAP sensor. INSTALLATION 1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple. 3. Install MAP sensor mounting bolts (screws). Tighten screws to 3 Nm (25 in. lbs.) torque. 4. Install air duct at throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams Engine Oil Pressure Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 2276 Oil Pressure Sensor: Description and Operation OIL PRESSURE SENSOR-PCM INPUT Sends a signal from the oil pressure sending unit to the Powertrain Control Module (PCM) relating to engine oil pressure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Oxygen Sensor 30 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2282 Oxygen Sensor: Locations Oxygen Sensor(s) Upstream Oxygen Sensor Locations Oxygen Sensor The upstream O2S sensor is located on exhaust downpipe. Downstream Oxygen Sensor Location Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2283 Downstream Oxygen Sensor The downstream O2S sensor is located on the outlet end of the catalytic converter. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2284 Oxygen Sensor: Diagrams Oxygen Sensor (Sensor Side) Oxygen Sensor 1/1 Upstream Oxygen Sensor 1/2 Downstream Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2285 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2286 Oxygen Sensor: Application and ID Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2287 Oxygen Sensor: Description and Operation OXYGEN SENSOR-PCM INPUT Two heated O2S sensors are used. The sensors produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel mixture), the sensors produces a low voltage. When there is a lesser amount present (rich air/fuel mixture) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. In Closed Loop operation, the PCM monitors the 02S sensor input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the 02 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. 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. The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. UPSTREAM HEATED OXYGEN SENSOR The upstream O2S sensor is located near the inlet end of the catalytic converter. It 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 the air/fuel ratio by adjusting injector pulse width. DOWNSTREAM HEATED OXYGEN SENSOR The downstream heated oxygen sensor is located near the outlet end of the catalytic converter. The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the Malfunction Indicator Lamp (MIL). For more information, refer to Emission Control Systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2288 Oxygen Sensor: Testing and Inspection To perform a complete test of the 02S sensors and their circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the O2S sensors only, refer to the following: Upstream Oxygen Sensor Location The upstream O2S sensor is located on the exhaust pipe. Downstream Oxygen Sensor Location The downstream O2S sensor is located on the outlet end of the catalytic converter. Each O2S heating element can be tested with an ohmmeter as follows: Disconnect the O2S sensor connector. Connect the ohmmeter test leads across the white wire terminals of the sensor connector. Resistance should be between 4.5 ± 0.5 ohms and 7 ohms. Replace the sensor if the ohmmeter displays an infinity (open) reading. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2289 Oxygen Sensor: Service and Repair Upstream Oxygen Sensor Locations Downstream Oxygen Sensor Locations The upstream O2S sensor is located on exhaust downpipe. The downstream sensor is located near outlet end of catalytic converter. REMOVAL WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support the vehicle. 2. Disconnect the wire connector from the O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install the O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Locations Central Timer Module: Locations Module Locations CENTRAL TIMER MODULE The Durango utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The Base CTM does not communicate on the CCD bus and will not be addressed. The CTM performs most of the typical functions a Body Control Module would perform. The module is located on the right side of the glove box behind a metal bracket. It contains a white 18-way and a green 14-way connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN WHILE IN MOTION. DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2296 Central Timer Module: 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module Central Timer Module: Description and Operation Central Timer Module DESCRIPTION Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the highline models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD 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. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. For diagnosis of the base version of the CTM, refer to Central Timer Module in the Diagnosis and Testing - Chime/Buzzer Warning Systems. For diagnosis of the high-line version of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-afterwash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermittent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. Refer to Central Timer module/Service and Repair of Instrument Panel Systems for the service procedures. See Wiper System Diagnosis and Testing for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. 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 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 Chrysler Collision Detection (CCD) 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. Refer to Remote Radio Switch in the Description and Operation for more information on this component. In addition, radio receivers connected to the CCD 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. The high-line CTM controls features and functions of the power lock, illuminated entry, and Remote Keyless Entry (RKE) systems. The high-line CTM receives hard wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio frequency inputs from the RKE transmitters. In response to those and many other inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the headlamp and horn relays, and the courtesy lamps. Some of the features and functions of the power lock, illuminated entry and RKE systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch when the driver door is open if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually, with a key, or energized with the RKE transmitter. - A programmable driver door unlock feature. The driver door unlock feature allows one press of the RKE transmitter Unlock button to unlock Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 2299 just the driver door, and a second press within five seconds to unlock all doors and the liftgate. If disabled, one press of the RKE transmitter Unlock button willunlock all doors and the liftgate. - A panic mode feature which can provide additional personal security and protection. When the Panic button on the RKE transmitter is depressed the vehicle horn will pulse, the headlights will flash, and the interior lights will illuminate on the vehicle for about three minutes, or until the Panic button is depressed a second time. A vehicle speed of about 24 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. - An enhanced accident response feature will unlock all doors and the liftgate, then prevent thepower door lock system from locking the doors and liftgate for a predetermined time interval, after receiving a CCD message from the ACM indicating a frontal impact of the vehicle requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates that the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors and the liftgate after the vehicle reaches a speed of about 24 kilometers-per-hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again, at any speed above 24 kilometers-per-hour (15 miles-per-hour). - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following activation of the RKE Lock function. This feature can be enabled or disabled and, if enabled, the horn chirp duration (twenty or forty milliseconds) can be selected. - Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the service procedures. - The programmable features of the CTM can be enabled or disabled using the DRB scan tool as described in the proper Diagnostic Procedures. These features can also be enabled/disabled using the customer programmable feature. See the owner's manual in the vehicle glove box for more information on the customer programmable feature. Refer to Central Timer Module in the Diagnosis and Testing for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. - One of the features that the high-line CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard- wired inputs from the door and liftgate ajar, door and liftgate lock cylinder, and ignition switches. The programming in the CTM allows it to process the information from these inputs and send control outputs to energize or de-energize the headlamp (or security) relay, horn relay, and the security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS - The high-line CTM also contains the receiver and control logic for the power lock and Remote Keyless Entry (RKE) systems, which are integrated into the arming, disarming, and triggering functions of the VTSS. - Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the service procedures. - For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. - One of the functions and features that both versions of the CTM support is the chime warning system. The CTM contains a chime tone generator to perform the functions of the chime warning module. The CTM uses hard-wired switch inputs, internal programming, and a hard-wired chime request input from the instrument cluster circuitry to detect when a chime tone is required. This covers the diagnosis and service of only the hard-wired inputs used by the CTM to determine that a chime tone should be generated. See Central Timer Module Diagnosis and Testing for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. OPERATION Some of the functions and features that the CTM supports or controls include: Chimes for the following conditions: - Headlamps on with ignition off and driver door open warning - Key in ignition with ignition off and driver door open warning - ABS lamp warning (if the vehicle is so equipped) - Airbag lamp warning - Check gauges lamp warning - Door ajar lamp warning - Low fuel lamp warning - Low washer fluid lamp warning - Seat belt reminder lamp warning Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 2300 - Transmission oil temperature lamp warning (automatic transmission) - Courtesy lamp defeat - Courtesy lamp time-out (high-line only) - Intermittent wipe control - Enhanced accident response (high-line only) - Horn chirp upon door lock with RKE (customer programmable) (high-line only) - Illuminated entry (high-line only) - Power door lock control (high-line only) - Power lock inhibit (high-line only) - Remote Keyless Entry (RKE) (high-line only) - Remote radio switches (high-line only) - Rolling door locks (customer programmable) (high-line only) - Speed sensitive intermittent wipe (high-line only) - Vehicle Theft Security System (VTSS) (high-line only) (if the vehicle is so equipped) - Wipe after wash (high-line only). More information on the operation of these CTM features and functions can be found in the system to which that feature or function applies. CENTRAL TIMER MODULE The Durango utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The Base CTM does not communicate on the CCD bus and will not be addressed. The CTM performs most of the typical functions a Body Control Module would perform. The Highline CTM provides the following features: Remote Keyless Entry (RKE) - Chime - Courtesy Lamp controls/Illuminated Entry - Power Door Locks - Speed Sensitive Intermittent Wipers - Enhanced Accident Response - Vehicle Theft Security System (VTSS) The module is located on the right side of the glove box behind a metal bracket. It contains a white 18-way and a green 14-way connector. Central Timer Module Diagnostic Trouble Codes - Door Disarm Switch Failure - Door Lock Switch Failure - Door Unlock Switch Failure - Wiper Park Switch Failure - EEPROM Checksum Failure - Internal ROM Test Failure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 2301 Central Timer Module: Description and Operation DRB III Error Messages and Blank Screen DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB will display one of only two error messages: User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, recored the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key itf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III Does Not Power Up (blank Screen) 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. Perform the "DRB Blank Screen" test under Vehicle Communication. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Information Bus/DRB Blank Screen DRB III Display Is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 2302 Central Timer Module: Description and Operation General Information Module Locations SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 1999 Durango consists of five modules that communicate over the CCD bus (Chrysler Collision Detection multiplex system). There are two additional modules, the Powertrain Control Module (PCM) and the Controller Anti-Lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication, The CAB also utilizes the bus for diagnostics. The PCM sends and receives messages on the CCD bus, however diagnostics are performed through the Serial Communication Interface (SCI), the same as previous years. All of the information about the functioning of all the systems is organized, controlled, and communicated by the CCD bus, which is described in Vehicle Communication. Through the CCD 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 the information to perform it's 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. 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 CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Mechanical Instrument Cluster (MIC) from the ACM via the CCD 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. Perform the WARNING LAMP CIRCUIT OPEN procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: warning lamp does not illuminate - warning lamp stays illuminated 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 2303 AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. CENTRAL TIMER MODULE The Durango utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The Base CTM does not communicate on the CCD bus and will not be addressed. The CTM performs most of the typical functions a Body Control Module would perform. The Highline CTM provides the following features: Remote Keyless Entry (RKE) - Chime - Courtesy Lamp controls/Illuminated Entry - Power Door Locks - Speed Sensitive Intermittent Wipers - Enhanced Accident Response - Vehicle Theft Security System (VTSS) The module is located on the right side of the glove box behind a metal bracket. It contains a white 18-way and a green 14-way connector. Chime system The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for seat belt, gauge problems and tell-tale warnings. There are two chime rates, Low; 50 ± 12 chimes per minute for reminders and High; 180 ± 12 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 doors are open or the headlights 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 approximately 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 - Seat belt warning - Check engine lamp illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Anti-lock lamp illuminated (after prove-out if equipped) - Check gauges lamp illuminated - Low fuel warning lamp illuminated - Low washer fluid - Door ajar 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/100Km since the last reset. Instantaneous Fuel Economy Shows the fuel economy for the last few seconds in MPG or L/100Km. 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 minitrip computer displays. US/M Button Press this button to convert all vehicle displays from US to Metric to US. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 2304 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, Trip Odometer, ET) is currently being displayed. 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. Enhanced Accident Response (Highline CTM Only) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the CCD bus to the CTM module to unlock the doors. The interior lights will be turned ON when the vehicle speed message on the CCD 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. Interior Lighting The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The highline CTM also provides for illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door disarm switch input or the door jamb switch input, the interior courtesy lights will be turned ON. The illuminated entry function is canceled if the CTM senses an ignition "ON" condition or the "lock" command from a valid key fob. If a door is left open or turned ON by rotation of dimmer switch for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned ON by courtesy lamp switch, the CTM will not be able to turn them OFF. The Durango utilizes an interior light defeat switch as an integral part of the headlamp switch. Mechanical Instrument Cluster (MIC) The MIC is available in 4 different versions. Two of the versions are Canadian clusters. There is a highline and a low line cluster available. The difference is the addition of a tachometer in the highline. In order to accomplish this, the fuel level gauge is reduced in size and oil pressure gauge is relocated. The cluster positions its gauges with bus messages received from the PCM. The odometer is a Liquid Crystal Display (LCD). The cluster will provide bus bias and the PCM provides termination. The MIC has an internal diagnostic routing that can be accessed by pushing and holding the trip odometer while rotating the key to the ON position. The cluster will then place all the gauges at their calibration points and will light all the CCD driven tell-tales. It will also light all the segments of the LCD display for a visual verification check. The MIC can verify communications with the PCM, ID the module, or change the country code by using options 1, 3, or 9 on the DRB III under the MIC menu. If there are faults found during the diagnostic routine, the cluster will report them on the LCD odometer display. Power Door Locks The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is OFF, the door is open, and the key is in the ignition. Automatic or "rolling locks" are included as a DRB III, or customer 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 CCD bus) indicating acceleration, the CTM will cycle the lock actuators to lock the doors. RKE/VTSS If the vehicle is equipped with Remote Keyless Entry (RKE), programming of additional transmitters and horn chirp are customer programmable features, The highline CTM provides for RKE and the Vehicle Theft Security System (VTSS). The base CTM is not able to provide these functions. The presence of either of these options dictates that the vehicle is equipped with a highline CTM. The VTSS system monitors the door ajar switches, liftgate 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, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes. After 15 minutes 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 2305 DRB III. The system may be disarmed by either an unlock command from a valid RKE key fob or by using a key in the lift gate or either door. Both front door key cylinders and the lift gate 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. The RKE system is placed in the programming mode by the DRB, or by using the customer programming sequence. The system will store up to four key fob codes. Two fobs are supplied with the truck, additional fobs may be purchased through parts department. The additional fobs can be programmed with the DRB III, or by using the customer programming sequence. 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. Speed Sensitive Intermittent Wipers The DN truck equipped with a highine CTM will utilize speed sensitive intermittent wipers. Only a highine CTM Will be able to support this feature. A base CTM will provide for intermittent wipers without the speed sensitive feature. 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. Diagnostics The CTM is fully addressable with the DRB III and it is the recommended method for diagnosis. The CTM reports 6 Diagnostic Trouble Codes. All of the inputs to the CTM can be read with the DRB and the outputs can be actuated. VEHICLE COMMUNICATION The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, and is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measureable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network" located in the module that supplies bus bias or voltage. Along with the module that supplies bias, some modules provide termination. Bias is the voltage necessary to make the bus operational. At least one point of termination is necessary, some systems may use more than one. Some modules are capable of both biasing and terminating. Termination in the circuitry (a 120 ohm resistor placed across the bus) is required to complete the voltage divider network circuit and also provide some electromagnetic protection for the bus. In this vehicle, the bias is supplied by the instrument cluster and termination is provided by the PCM and the instrument cluster. Without termination, voltage on the bus goes to approximately 5 volts on one wire and 0 volts on the other wire. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB III. Problems with the operation of the bus or DRB III must corrected before proceeding with diagnostic testing. Bus Failure Messages Short to Battery - Either or both of the bus wires are shorted to the battery potential, or Open ground to any CCD bus module. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of the bus wires are shorted to ground. Bus (+) L Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with the Instrument Cluster. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 2306 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. The procedure begins with AIRBAG TEST 1A-Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. 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 for 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 occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. 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 the 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, the 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. Airbag Diagnostic Trouble Codes The airbag control module may report any of the following diagnostic trouble codes. For the following codes, replace the Airbag Control Module (ACM) even if set intermittently: ACM Accelerometer - Internal Diagnostic 1 - Internal Diagnostic 2 For the following codes, replace the Airbag Control Module (ACM): ACM Output Driver - ACM Stored Energy Logic - ACM Stored Energy Driver - ACM Stored Energy Passenger - Internal Diagnostic 3 - Internal Diagnostic 4 - Safing Sensor Shorted - Warning Lamp Driver Error For these codes, refer to the appropriate diagnostic procedure: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Central Timer Module > Page 2307 - Driver Squib Open - Driver Squib Shorted - Loss of Ignition Run Only - Loss of Ignition Run/Start - No CCD Communication - Passenger Squib Circuit Open - Passenger Squib Circuit Shorted - Either Squib Terminal Short to Battery - Either Squib Terminal Short to Ground - Warning Lamp Circuit Open - Warning Circuit Shorted Central Timer Module Diagnostic Trouble Codes - Door Disarm Switch Failure - Door Lock Switch Failure - Door Unlock Switch Failure - Wiper Park Switch Failure - EEPROM Checksum Failure - Internal ROM Test Failure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 AM/FM Switch Inoperative SYMPTOM AM-FM SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Balance Dial Inoperative SYMPTOM BALANCE DIAL INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative CD Eject Switch Inoperative SYMPTOM CD EJECT SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Equalizer Inoperative SYMPTOM EQUALIZER INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative External CD Changer (If Equipped) SYMPTOM * EXTERNAL CD CHANGER (IF EQUIPPED) POSSIBLE CAUSES - CD cable assembly defective - CD changer defective - Defective radio Fader Dial Inoperative SYMPTOM FADER DIAL INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative FF/RW Switch Inoperative SYMPTOM Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2310 FF/RW SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Hour/Minute Switch Inoperative SYMPTOM HOUR/MINUTE SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative No Sound From All Speakers SYMPTOM * NO SOUND FROM ALL SPEAKERS POSSIBLE CAUSES - Radio 12 V output circuit defective - Radio defective - Radio defective - Fused B(+) circuit open - Ground circuit open - Defective radio No Sound From One Speaker SYMPTOM * NO SOUND FROM ONE SPEAKER POSSIBLE CAUSES - Pillar speaker (+) circuit open - Pillar speaker (-) circuit open - Pillar speaker defective - Speaker (-) circuit shorted - Speaker defective - Amplifier speaker (+) circuit open - Amplifier speaker (-) circuit open - Power amplifier defective - Power amplifier defective Pause/Play Switch Inoperative SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Poor Sound Quality All Speakers SYMPTOM * POOR SOUND QUALITY ALL SPEAKERS POSSIBLE CAUSES - Antenna connector connection defective - Radio 12 V output circuit defective - Radio connections defective - Radio defective Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2311 - Radio defective - Fused B(+) circuit open - Ground circuit open - Radio choke relay connection defective Poor Sound Quality From One Speaker SYMPTOM * POOR SOUND QUALITY FROM ONE SPEAKER POSSIBLE CAUSES - Pillar/lower speaker (+) circuit open - Pillar lower speaker (-) circuit open - Pillar speaker defective - Radio defective - Radio defective - Speaker (+) circuit open - Speaker (-) circuit open - Speaker defective PWR Switch Inoperative SYMPTOM PWR SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Remote Steering Wheel Switches (If Equipped) SYMPTOM * REMOTE STEERING WHEEL SWITCHES (IF EQUIPPED) POSSIBLE CAUSES - MUX control clockspring defective - Radio control circuit defective open - Radio control switch ground circuit open - Radio MUX control circuit defective - Remote control switch defective - No response CCD bus failure - Radio control MUX circuit open - Central timer module defective Scan Switch Inoperative SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Seek Switch Inoperative SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2312 Set Switch Inoperative SYMPTOM SET SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Shorted Front Channel SYMPTOM SHORTED FRONT CHANNEL POSSIBLE CAUSES - Radio defective - Right front SPKR (+) circuit short to ground - Right front SPKR (-) circuit short to ground - Left front SPKR (+) circuit short to ground - Left front SPKR (-) circuit short to ground Shorted Left Channel SYMPTOM SHORTED LEFT CHANNEL POSSIBLE CAUSES - Left rear SPKR (+) circuit short to ground - Left rear SPKR (-) circuit short to ground - Left front SPKR (+) circuit short to ground - Left front SPKR (-) circuit short to ground - Radio defective Shorted Rear Channel SYMPTOM SHORTED REAR CHANNEL POSSIBLE CAUSES - Left rear SPKR (+) circuit short to ground - Left rear SPKR (-) circuit short to ground - Radio defective - Right rear SPKR (+) circuit short to ground - Right rear SPKR (-) circuit short to ground Shorted Right Channel SYMPTOM SHORTED RIGHT CHANNEL POSSIBLE CAUSES - Right rear SPKR (+) circuit short to ground - Right rear SPKR (-) circuit short to ground - Right front SPKR (+) circuit short to ground - Radio defective - Right front SPKR (-) circuit short to ground Tape Eject Switch Inoperative SYMPTOM TAPE EJECT SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2313 Tune Switch Inoperative SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Volume/Time Switch Inoperative SYMPTOM VOL/TIME SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative 1-5 Presets Inoperative SYMPTOM 1-5 PRESETS INOPERATIVE POSSIBLE CAUSES - Radio function controls inoperative Chime Inoperative - Engine Temperature Critical SYMPTOM * CHIME INOPERATIVE - ENGINE TEMPERATURE CRITICAL POSSIBLE CAUSES - Tone request circuit open - Instrument cluster tone request output defective - CTM fails chime test - PCM DTC - coolant temp check Chime Inoperative - Key In Ignition & LF Door Open SYMPTOM * CHIME INOPERATIVE - KEY IN IGNITION & LF DOOR OPEN POSSIBLE CAUSES - Key in ignition SW sense CKT open - Ignition SW-key in SW open - CTM no chime to key in ignition - CTM not responding to key in SW Chime Inoperative at All Times SYMPTOM * CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM fails internal chime test Chime Inoperative With Exterior Lamps On SYMPTOM * CHIME INOPERATIVE WITH EXTERIOR LAMPS ON POSSIBLE CAUSES - Headlamp switch circuit open Chime Inoperative With Low Oil Pressure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2314 SYMPTOM * CHIME INOPERATIVE WITH LOW OIL PRESSURE POSSIBLE CAUSES - Oil pressure sender ground circuit open - Tone request circuit open - Instrument cluster - oil press defective - CTM no response to oil pressure default - CTM fails chime test Chime Sounds With Driver Door Open SYMPTOM * CHIME SOUNDS WITH DRIVER DOOR OPEN POSSIBLE CAUSES - Key in ignition switch sense circuit short to ground - Ignition SW - key in SW shorted - CTM - key in sense short default - CTM not responding to key out Open Driver Door Ajar Circuit SYMPTOM * OPEN DRIVER DOOR AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Left front ajar switch sense circuit open - Left front door ajar switch defective shorted - Left front door ajar switch sense circuit open Open Gate Ajar Circuit SYMPTOM * OPEN GATE AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Liftgate ajar switch sense circuit defective open - Liftgate door ajar ground circuit defective open - Liftgate door ajar switch defective open Open Left Rear Door Ajar Circuit SYMPTOM * OPEN LEFT REAR DOOR AJAR CIRCUIT POSSIBLE CAUSES - Left rear door ajar switch sense circuit defective open - CTM defective - Ground circuit defective open - Left rear door ajar switch defective open Open Right Front Door Ajar Circuit SYMPTOM * OPEN RIGHT FRONT DOOR AJAR CIRCUIT POSSIBLE CAUSES - RF door ajar switch sense (ground circuit) open - Right front door ajar switch sense circuit open - CTM defective - Right front door ajar switch defective open Open Right Rear Door Ajar Circuit SYMPTOM * OPEN RIGHT REAR DOOR AJAR CIRCUIT Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2315 POSSIBLE CAUSES - Right rear door ajar switch sense circuit defective open - CTM defective - Ground circuit defective open - Right rear door ajar switch defective open Shorted Driver Door Ajar Circuit SYMPTOM * SHORTED DRIVER DOOR AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Left front door ajar switch defective shorted - LF door ajar switch sense circuit short to GND Shorted Gate Ajar Circuit SYMPTOM * SHORTED GATE AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Liftgate ajar switch defective shorted - Liftgate ajar switch sense circuit defective short to GND Shorted Passenger Door Ajar Circuit SYMPTOM * SHORTED PASSENGER DOOR AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Door ajar switch sense circuit short to ground - Right front door ajar switch defective shorted - Right rear door ajar switch DEF shorted - Left rear door ajar switch DEF shorted All Gauges Inoperative SYMPTOM * ALL GAUGES INOPERATIVE POSSIBLE CAUSES - No response/CCD bus (MIC) - Fuse #17 open - Fused ignition switch output circuit open - Instrument cluster defective Any CCD Cluster Warning Lamp Inoperative SYMPTOM * ANY CCD CLUSTER LAMP INOPERATIVE POSSIBLE CAUSES - No response/CCD bus (MIC) - CCD inoperative lamp/bulb defective - CCD lamp cluster input defective - Defective cluster - CCD LP cluster test complete Any Hard Wired Cluster Warning Lamp SYMPTOM * ANY HARD WIRED LAMP INOPERATIVE POSSIBLE CAUSES - Hard wired lamp circuit open Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2316 - Inoperative lamp/bulb defective - Defective instrument cluster One Gauge Not Operating Properly SYMPTOM * ONE GAUGE NOT OPERATING PROPERLY POSSIBLE CAUSES - Gauge not reading 4 PSI> engine warm at idle - Oil gauge not reading 4 PSI Or > at idle - Oil level low - Instrument cluster circuit board defective - Oil pressure sensor defective - Instrument cluster defective - Oil pressure sense circuit open - Oil pressure sense signal CKT short to ground - Cooling system operation faulty - DRB shows ECT sensor voltage too high - DRB shows ECT sensor voltage too low - Check for PCM DTC'S - Defective JTEC module - Fuel gauge inoperative - JTEC module defective - Oil pressure switch defective - Pinion factor incorrect - Powertrain control module defective - Tachometer inoperative - Voltage gauge inoperative Average MPH/Fuel Econ Inoperative or Wrong SYMPTOM * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG POSSIBLE CAUSES - Defective compass/mini-trip computer CMTC Display Shows Failed SYMPTOM * CMTC DISPLAY SHOWS FAILED POSSIBLE CAUSES - Defective CMTC display failed CMTC Fails to Respond to Instrument Panel Dimming SYMPTOM * CMTC FAILS TO RESPOND TO INSTRUMENT PANEL DIMMING TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer CMTC Segments Fail to Light Up SYMPTOM * CMTC SEGMENTS FAIL TO LIGHT UP POSSIBLE CAUSES - Defective compass mini-trip computer-segments fail to light Distance to Empty Inoperative or Wrong SYMPTOM * DISTANCE TO EMPTY INOPERATIVE OR WRONG Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2317 TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer Elapsed Time Inoperative/Wrong SYMPTOM * ELAPSED TIME INOPERATIVE/WRONG TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer Repairing OC In CMTC Display SYMPTOM * REPAIRING "OC" IN CMTC DISPLAY POSSIBLE CAUSES - Open sensor ground circuit - Defective ambient temperature sensor-SC - Open ambient temperature sensor signal circuit - Defective CMTM/OC default Repairing SC In CMTC Display SYMPTOM * REPAIRING "OC" IN CMTC DISPLAY POSSIBLE CAUSES - Ambient temperature sensor signal CKT-SH/sensor GND - Defective ambient temperature sensor-OC - Ambient temperature sensor signal CKT-short/GND - Defective CMTM/SC default Switch on Compass Mini-Trip Computer Inoperative SYMPTOM * SWITCH ON COMPASS MINI-TRIP COMPUTER INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer Trip Odometer Inoperative/Wrong SYMPTOM * TRIP ODOMETER INOPERATIVE/WRONG TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer Automatic (Rolling) Door Locks Inoperative SYMPTOM * AUTOMATIC (ROLLING) DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Link to body communication bus inoperative Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2318 - Speed sensing door locks inoperative Doors Lock With Key In Ignition and Left Door Open SYMPTOM * DOORS LOCK WITH KEY IN IGNITION AND LEFT DOOR OPEN POSSIBLE CAUSES - Link to body communication bus inoperative - Ignition switch shorted - Key-in ignition switch sense circuit open - CTM input A9 short to ground - CTM input shorted to ground One or All Doors Failing to Lock From One Switch SYMPTOM * ONE OR ALL DOORS FAILING TO LOCK FROM ONE SWITCH POSSIBLE CAUSES - Link to body communication bus inoperative - Door lock actuator assembly defective - Door unlock actuator assembly defective - Door lock switch assembly open - Door unlock switch assembly open - Door lock driver circuit open - Fused B (+) circuit open - Door lock driver circuit open - Power door lock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - CTM lock driver input open - CTM unlock driver input open - Lock driver circuit on CTM open - Unlock driver circuit on CTM open One or All Doors Failing to Unlock From One Switch SYMPTOM * ONE OR ALL DOORS FAILING TO UNLOCK FROM ONE SWITCH TEST NOTE: This symptom is diagnosed using the test * ONE OR ALL DOORS FAILING TO LOCK FROM ONE SWITCH. POSSIBLE CAUSES - Link to body communication bus inoperative - Door lock actuator assembly defective - Door unlock actuator assembly defective - Door lock switch assembly open - Door unlock switch assembly open - Door lock driver circuit open - Fused B (+) circuit open - Door lock driver circuit open - Power door lock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - CTM lock driver input open - CTM unlock driver input open - Lock driver circuit on CTM open - Unlock driver circuit on CTM open Remote Keyless Entry Problem SYMPTOM * REMOTE KEYLESS ENTRY PROBLEM POSSIBLE CAUSES - Link to body communication bus inoperative Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2319 - Transmitter defective - Circuit between CTM & left front UNLCK RLY open - Door unlock relay defective - Door unlock relay internal defect - Left front door unlock relay coil out of tolerance - Left front door unlock relay B (+) circuit open - Unlock relay B (+) circuit open (CAV 87) - CTM defective-RKE function - CTM unlock relay signal inoperative - Left front door unlock relay circuit at CTM open Intermittent Wipers Inoperative SYMPTOM * INTERMITTENT WIPERS INOPERATIVE POSSIBLE CAUSES - No response/CCD bus failure - CTM - Open intermittent wiper mode sense CKT - Open wiper park switch sense CKT - Defective wiper motor/12 volts - Defective CTM/12 volt default - Defective CTM/STALK switch - Defective multi-function switch/5.0 ohms No Wipe After Washers Actuated SYMPTOM * NO WIPE AFTER WASHERS ACTUATED POSSIBLE CAUSES - CCD bus failure-no response CTM - Open front washer switch sensor CKT - Defective CTM/washer pump Wiper Speed Sensitive Feature Inoperative SYMPTOM * WIPER SPEED SENSITIVE FEATURE INOPERATIVE POSSIBLE CAUSES - CCD bus failure-CTM - CCD bus failure PCM - Defective CTM/wiper intervals Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2320 Central Timer Module: Component Tests and General Diagnostics 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 SCREEN WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2321 Central Timer Module: Scan Tool Testing and Procedures Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, recored the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key itf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III Does Not Power Up (blank Screen) 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. Perform the "DRB Blank Screen" test under Vehicle Communication. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Information Bus/DRB Blank Screen DRB III Display Is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2322 Central Timer Module: Tools and Equipment DRB III (Diagnostic Read Out Box) Jumper Wires Ohmmeter Voltmeter Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Specifications Powertrain Control Module: Specifications Powertrain Control Module Mounting Screws 1 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Specifications > Page 2326 Powertrain Control Module: Locations PCM Location And Mounting Powertrain Control Module The PCM is located in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2329 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2330 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2331 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2332 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2333 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2334 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2335 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2336 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2337 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2338 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2339 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2340 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2341 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2342 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2343 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2344 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2345 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2346 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2347 Powertrain Control Module: Connector Views Powertrain Control Module C1 Powertrain Control Module C2 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2348 Powertrain Control Module C3 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2349 Powertrain Control Module: Service and Repair PCM Location And Mounting The PCM is located in the engine compartment. REMOVAL 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 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. IMPORTANT NOTE: If the Powertrain Control Module has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the ABS and Air bag modules. In addition, if the vehicle is equipped with a Sentry Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. FOR ABS AND AIR BAG SYSTEMS: 1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS and Air Bag modules. FOR SKIM THEFT ALARM: 1. Connect the DRBIII to the data link connector. 2. Go to Theft Alarm, SKIM, Misc. and place the SKIM in secured access mode, by using the appropriate PIN code for this vehicle. 3. Select Update the Secret Key data, data will be transferred from the SKIM to the PCM (This is required to allow the vehicle to start with the new PCM). 4. If three attempts are made to enter secured access mode using the incorrect PIN, secured access mode will be locked out for one hour. To exit this lock out mode, leave the ignition key in the Run/Start position for one hour. Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Power Distributor Center (PDC) Location Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2353 Power Distribution Center The ASD relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2354 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down (ASD) Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2355 Automatic Shut Down (ASD) Relay: Description and Operation AUTOMATIC SHUTDOWN (ASD) RELAY SENSE-PCM INPUT Power Distribution Center(PDC) A 12 volt signal at this input indicates to the Powertrain Control Module (PCM) that the ASD has been activated. The ASD relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. 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 PCM does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). AUTO SHUTDOWN (ASD) RELAY-PCM OUTPUT The ASD relay is located in the Power Distribution Center (PDC). The ASD supplies battery voltage to the fuel injectors, ignition coil and oxygen (O2S) sensor heating elements. The ground circuit for the coil in the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the relay by switching the ground circuit on and off. AUTOMATIC SHUTDOWN (ASD) RELAY As one of its functions, the ASD relay will supply battery voltage to the ignition coil. The ground circuit for the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM regulates ASD relay operation by switching the ground circuit on-and-off. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2356 Automatic Shut Down (ASD) Relay: Testing and Inspection ASD And Fuel Pump Relay Terminals 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. Operation 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. Testing The following procedure applies to the ASD and fuel pump relays. 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 ± 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 source5 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2357 Automatic Shut Down (ASD) Relay: Service and Repair Power Distributor Center (PDC) Location The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. REMOVAL 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 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Battery Temperature Sensor The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2362 Battery Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2363 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2364 Battery Temperature Sensor: Description and Operation DESCRIPTION The battery temperature sensor is attached to the battery tray located under the battery. OPERATION The battery temperature sensor 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. BATTERY TEMPERATURE SENSOR-PCM INPUT Provides a signal to the PCM corresponding to the battery temperature. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor 1. The sensor is located on the front of the battery tray. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25° C (75-80° F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 2367 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. REMOVAL 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor Oil Pressure Sending Unit/Switch, Camshaft Position Sensor Connector The camshaft position sensor is located in the distributor on all engines. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2371 Camshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2372 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor CAMSHAFT POSITION SENSOR - PCM INPUT A sync signal is provide by the camshaft position sensor located in the distributor. The sync signal from this sensor works in conjunction with the crankshaft position sensor to provide the Powertrain Control Module (PCM) with inputs. This is done to establish and maintain correct injector firing order. CAMSHAFT POSITION SENSOR The camshaft position sensor is located in the distributor on all engines. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2373 Camshaft Position Sensor: Testing and Inspection Camshaft Position Sensor The camshaft position sensor is located in the distributor on all engines. To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: For this test, an analog (non-digital) voltmeter is needed. Do not remove the distributor connector from the distributor. Using small paper clips, insert them into the backside of the distributor wire harness connector to make contact with the terminals. Be sure that the connector is not damaged when inserting the paper clips. Attach voltmeter leads to these paper clips. 1. Connect the positive (+) voltmeter lead into the sensor output wire. This is at done the distributor wire harness connector. 2. Connect the negative (-) voltmeter lead into the ground wire. 3. Set the voltmeter to the 15 Volt DC scale. 4. Remove distributor cap from distributor (two screws). Rotate (crank) the engine until the distributor rotor is pointed towards the rear of vehicle. The movable pulse ring should now be within the sensor pickup. 5. Turn ignition key to ON position. Voltmeter should read approximately 5.0 volts. 6. If voltage is not present, check the voltmeter leads for a good connection. 7. If voltage is still not present, check for voltage at the supply wire. For wire identification, refer to Wiring Diagrams. 8. If 5 volts is not present at supply wire, check for voltage at PCM 32-way connector (cavity A-17). Leave the PCM connector connected for this test. 9. If voltage is still not present, perform vehicle test using the DRB scan tool. 10. If voltage is present at cavity A-17, but not at the supply wire: a. Check continuity between the supply wire. This is checked between the distributor connector and cavity A-17 at the PCM. If continuity is not present, repair the harness as necessary. b. Check for continuity between the camshaft position sensor output wire and cavity A-18 at the PCM, If continuity is not present, repair the harness as necessary. c. Check for continuity between the ground circuit wire at the distributor connector and ground. If continuity is not present, repair the harness as necessary. 11. While observing the voltmeter, crank the engine with ignition switch. The voltmeter needle should fluctuate between 0 and 5 volts while the engine is cranking. This verifies that the camshaft position sensor in the distributor is operating properly and a sync pulse signal is being generated. If sync pulse signal is not present, replacement of the camshaft position sensor is necessary Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2374 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor The camshaft position sensor is located in the distributor on all engines. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove air cleaner assembly. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. tighten mounting screws. 5. Install air cleaner assembly. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 11 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2378 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor-Typical Intake Air Temperature Sensor, Engine Coolant Temperature Sensor Connector, Ignition Coil The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2379 Engine Coolant Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2380 Coolant Temperature Sensor/Switch (For Computer): Service Precautions WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2381 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT The engine coolant temperature sensor is installed into a water jacket at the front of the intake manifold located near the rear of the generator. The sensor provides an input voltage to the Powertrain Control Module (PCM) relating coolant temperature. The PCM uses this input along with inputs from other sensors to determine injector pulse width and ignition timing. As coolant temperature varies, the coolant temperature sensor resistance will change. This change in resistance results in a different input voltage to the PCM. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2382 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: Engine Coolant Temperature Sensor-Typical 1. Disconnect wire harness connector from coolant temperature sensor. 2. Engines with air conditioning: When removing the connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place the hook part of tool under the connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. Sensor Resistance(Ohms)-Coolant Temperature Sensor/Intake Air Temperature Sensor 3. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. The resistance (as measured across the sensor terminals) should be as shown in the SENSOR RESISTANCE (OHMS)-COOLANT TEMPERATURE SENSOR/INTAKE AIR TEMPERATURE SENSOR resistance chart. Replace the sensor if it is not within the range of resistance specified in the chart. 4. Test continuity of the wire harness between the PCM wire harness connector and the coolant sensor connector terminals. Refer to Wiring for terminal/cavity locations. Repair the wire harness if an open circuit is indicated. 5. After tests are completed, connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2383 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor-Typical The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain cooling system. 2. Disconnect electrical connector from sensor. 3. Engines with air conditioning: When removing the connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place the hook part of tool under the connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Use long needle nose pliers to connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. 4. Replace any lost engine coolant. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor 8 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2387 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The sensor is bolted to the cylinder block near the rear of the right cylinder head. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2388 Crankshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2389 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR 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. Sensor Operation The flywheel/drive plate has 8 single notches, spaced every 45 degrees, 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. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a crankshaft position sensor input. CRANKSHAFT POSITION SENSOR-PCM INPUT This sensor is a hall effect device that detects notches in the flywheel (manual transmission) or flexplate (automatic transmission). This sensor is used to indicate to the Powertrain Control Module (PCM) that a spark and or fuel injection event is to be required. The output from this sensor, in conjunction with the camshaft position sensor signal, is used to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2390 Crankshaft Position Sensor The sensor is bolted to the cylinder block near the rear of the right cylinder head. Refer to Ignition System for more crankshaft position sensor information. The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2391 Crankshaft Position Sensor: Testing and Inspection To perform a complete test of this sensor and its circuitry, refer to the DRB scan tool. Also refer to the appropriate Powertrain Diagnostics Procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2392 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. 1. Remove right front tire and right front wheelhouse liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheelhouse liner. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR-PCM INPUT The Powertrain Control Module (PCM) supplies power to the fuel level sensor (fuel gauge sending unit). The fuel level sensor will then return a signal to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes. This is if the fuel level is less than approximately 15 percent, or, if equipped with a Leak Detection Pump (LDP), more than approximately 85 percent of its rated capacity. This input is also used to send a signal to the PCM for fuel gauge operation via the CCD bus circuits. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Intake Manifold Air Temperature Sensor 28 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2399 Intake Air Temperature Sensor: Locations Intake Manifold Air Temperature Sensor-Typical Intake Air Temperature Sensor, Engine Coolant Temperature Sensor Connector, Ignition Coil The intake manifold air temperature sensor is located in the front/side of the intake manifold. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2400 Intake Air Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2401 Intake Air Temperature Sensor: Description and Operation Intake Manifold Air Temperature Sensor INTAKE MANIFOLD AIR TEMPERATURE SENSOR-PCM INPUT The intake manifold air temperature sensor is installed in the intake manifold with the sensor element extending into the air stream. The sensor provides an input voltage to the Powertrain Control Module (PCM) indicating intake manifold air temperature. The input is used along with inputs from other sensors to determine injector pulse width. As the temperature of the air-fuel stream in the manifold varies, the sensor resistance changes. This results in a different input voltage to the PCM. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2402 Intake Air Temperature Sensor: Testing and Inspection To perform a complete test of the intake manifold air temperature sensor and its circuitry, refer to DRB tester and appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: Intake Manifold Air Temperature Sensor 1. Disconnect the wire harness connector from the intake manifold air temperature sensor. Sensor Resistance(Ohms)-Coolant Temperature Sensor/Intake Air Temperature Sensor 2. Test the resistance of the sensor with an input impedance (digital) volt-ohmmeter. The resistance (as measured across the sensor terminals) should be as shown in the previous SENSOR RESISTANCE (OHMS-COOLANT TEMPERATURE SENSOR/INTAKE AIR TEMPERATURE SENSOR chart. Replace the sensor if it is not within the range of resistance specified in the chart. 3. Test the resistance of the wire harness. Do this between the PCM wire harness connector A-15 and the sensor connector terminal. Also check between PCM connector A-4 to the sensor connector terminal. Repair the wire harness as necessary if the resistance is greater than 1 ohm. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2403 Intake Air Temperature Sensor: Service and Repair Intake Manifold Air Temperature Sensor-Typical The intake manifold air temperature sensor is located in the front/side of the intake manifold. REMOVAL 1. Remove air duct at throttle body. 2. Disconnect electrical connector at sensor 3. Remove sensor from intake manifold. INSTALLATION 1. Install sensor to intake manifold. Tighten to 28 Nm (20 ft. lbs.) torque. 2. Install electrical connector. 3. Install air duct at throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications MAP Sensor Mounting Screws 3 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2407 Manifold Pressure/Vacuum Sensor: Locations MAP And Throttle Position Sensor Location The MAP sensor is mounted on the side of the engine throttle body. The sensor is connected to the throttle body with a rubber L-shaped fitting. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2408 Manifold Absolute Pressure Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2409 Manifold Pressure/Vacuum Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR-PCM INPUT The MAP sensor reacts to absolute pressure in the intake manifold. It provides an input voltage to the Powertrain Control Module (PCM). As engine load changes, manifold pressure varies. The change in manifold pressure causes MAP sensor voltage to change. The change in MAP sensor voltage results in a different input voltage to the PCM. The input voltage level supplies the PCM with information about ambient barometric pressure during engine start-up (cranking) and engine load while the engine is running. The PCM uses this input along with inputs from other sensors to adjust air-fuel mixture. MAP And Throttle Position Sensor Location The MAP sensor is mounted on the side of the engine throttle body. The sensor is connected to the throttle body with a rubber L-shaped fitting. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2410 Manifold Pressure/Vacuum Sensor: Testing and Inspection MAP Sensor-Typical To perform a complete test of MAP sensor and its circuitry, refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the MAP sensor only, refer to the following: Rubber L-shaped Fitting-MAP Sensor-to-Throttle Body 1. Inspect the rubber L-shaped fitting from the MAP sensor to the throttle body. Repair as necessary. CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2411 MAP Sensor Connector Terminals-Typical 2. Test the MAP sensor output voltage at the MAP sensor connector between terminals A and B. With the ignition switch ON and the engine OFF, output voltage should be 4-to-5 volts. The voltage should drop to 1.5-to-2.1 volts with a hot, neutral idle speed condition. 3. Test Powertrain Control Module (PCM) cavity A-27 for the same voltage described above to verify the wire harness condition. Repair as necessary. 4. Test MAP sensor supply voltage at sensor connector between terminals A and C with the ignition ON. The voltage should be approximately 5 volts (± 0.5V). Five volts (± 0.5V) should also be at cavity A-17 of the PCM wire harness connector. Repair or replace the wire harness as necessary. 5. Test the MAP sensor ground circuit at sensor connector terminal-A and PCM connector A-4. Repair the wire harness if necessary Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2412 Manifold Pressure/Vacuum Sensor: Service and Repair MAP Sensor Location MAP Sensor L-Shaped Rubber Fitting The MAP sensor is located on the front of the throttle body. An L-shaped rubber fitting is used to connect the MAP sensor to throttle body. REMOVAL 1. Remove air duct at throttle body. 2. Remove two MAP sensor mounting bolts (screws). 3. While removing MAP sensor, slide the vacuum rubber L-shaped fitting from the throttle body. 4. Remove rubber L-shaped fitting from MAP sensor. INSTALLATION 1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple. 3. Install MAP sensor mounting bolts (screws). Tighten screws to 3 Nm (25 in. lbs.) torque. 4. Install air duct at throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 2416 Oil Pressure Sensor: Description and Operation OIL PRESSURE SENSOR-PCM INPUT Sends a signal from the oil pressure sending unit to the Powertrain Control Module (PCM) relating to engine oil pressure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2422 Oxygen Sensor: Locations Oxygen Sensor(s) Upstream Oxygen Sensor Locations Oxygen Sensor The upstream O2S sensor is located on exhaust downpipe. Downstream Oxygen Sensor Location Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2423 Downstream Oxygen Sensor The downstream O2S sensor is located on the outlet end of the catalytic converter. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2424 Oxygen Sensor: Diagrams Oxygen Sensor (Sensor Side) Oxygen Sensor 1/1 Upstream Oxygen Sensor 1/2 Downstream Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2425 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2426 Oxygen Sensor: Application and ID Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2427 Oxygen Sensor: Description and Operation OXYGEN SENSOR-PCM INPUT Two heated O2S sensors are used. The sensors produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel mixture), the sensors produces a low voltage. When there is a lesser amount present (rich air/fuel mixture) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. In Closed Loop operation, the PCM monitors the 02S sensor input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the 02 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. 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. The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. UPSTREAM HEATED OXYGEN SENSOR The upstream O2S sensor is located near the inlet end of the catalytic converter. It 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 the air/fuel ratio by adjusting injector pulse width. DOWNSTREAM HEATED OXYGEN SENSOR The downstream heated oxygen sensor is located near the outlet end of the catalytic converter. The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the Malfunction Indicator Lamp (MIL). For more information, refer to Emission Control Systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2428 Oxygen Sensor: Testing and Inspection To perform a complete test of the 02S sensors and their circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the O2S sensors only, refer to the following: Upstream Oxygen Sensor Location The upstream O2S sensor is located on the exhaust pipe. Downstream Oxygen Sensor Location The downstream O2S sensor is located on the outlet end of the catalytic converter. Each O2S heating element can be tested with an ohmmeter as follows: Disconnect the O2S sensor connector. Connect the ohmmeter test leads across the white wire terminals of the sensor connector. Resistance should be between 4.5 ± 0.5 ohms and 7 ohms. Replace the sensor if the ohmmeter displays an infinity (open) reading. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2429 Oxygen Sensor: Service and Repair Upstream Oxygen Sensor Locations Downstream Oxygen Sensor Locations The upstream O2S sensor is located on exhaust downpipe. The downstream sensor is located near outlet end of catalytic converter. REMOVAL WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support the vehicle. 2. Disconnect the wire connector from the O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install the O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2433 Throttle Position Sensor: Locations MAP And Throttle Position Sensor Location The throttle position sensor (TPS) is mounted on the throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2434 Throttle Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2435 Throttle Position Sensor: Description and Operation MAP And Throttle Position Sensor Location THROTTLE POSITION SENSOR (TPS)-PCM INPUT The throttle position sensor (TPS) is mounted on the throttle body. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents throttle blade position. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2436 Throttle Position Sensor: Testing and Inspection To perform a complete test of the TPS and its circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the TPS only, refer to the following: Throttle Position Sensor The TPS can be tested with a digital voltmeter. The center electrical terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). At idle, TPS output voltage should be greater than 0.26 volts but less than 0.95 volts. At wide open throttle, TPS output voltage must be less than 4.49 volts. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2437 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on side of throttle body. 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body. INSTALLATION Installation-Typical The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2441 Transmission Position Switch/Sensor: Description and Operation TRANSMISSION PARK/NEUTRAL SWITCH-PCM INPUT The park/neutral switch is located on the transmission housing and provides an input to the Powertrain Control Module (PCM), This will indicate that the automatic transmission is in Park, Neutral or a drive gear selection. This input is used to determine idle speed (varying with gear selection), fuel injector pulse width, ignition timing advance and vehicle speed control operation. The center terminal of the park/neutral position switch is the starter-circuit terminal. It provides the ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. The outer terminals on the switch are for the backup lamp circuit. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2442 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for speed control system operation. For the location of the transmission output shaft sensor, please refer to Transmission Speed Sensor/Locations. See: Transmission Control Systems/Sensors and Switches - Transmission and Drivetrain/Sensors and Switches - A/T/Transmission Speed Sensor For the location of the rear wheel speed sensor, please refer to Brakes and Traction Control/Brakes/Antilock Brake System/Wheel Speed Sensor/Locations. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2448 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2449 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2450 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2451 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2452 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2453 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2454 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2455 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2456 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2457 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2458 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2459 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2460 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2461 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2462 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2463 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2464 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2465 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2466 Vehicle Speed Sensor: Description and Operation VEHICLE SPEED AND DISTANCE-PCM INPUT Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for fuel system and speed control system operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2470 Throttle Position Sensor: Locations MAP And Throttle Position Sensor Location The throttle position sensor (TPS) is mounted on the throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2471 Throttle Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2472 Throttle Position Sensor: Description and Operation MAP And Throttle Position Sensor Location THROTTLE POSITION SENSOR (TPS)-PCM INPUT The throttle position sensor (TPS) is mounted on the throttle body. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents throttle blade position. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2473 Throttle Position Sensor: Testing and Inspection To perform a complete test of the TPS and its circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the TPS only, refer to the following: Throttle Position Sensor The TPS can be tested with a digital voltmeter. The center electrical terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). At idle, TPS output voltage should be greater than 0.26 volts but less than 0.95 volts. At wide open throttle, TPS output voltage must be less than 4.49 volts. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2474 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on side of throttle body. 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body. INSTALLATION Installation-Typical The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2478 Transmission Position Switch/Sensor: Description and Operation TRANSMISSION PARK/NEUTRAL SWITCH-PCM INPUT The park/neutral switch is located on the transmission housing and provides an input to the Powertrain Control Module (PCM), This will indicate that the automatic transmission is in Park, Neutral or a drive gear selection. This input is used to determine idle speed (varying with gear selection), fuel injector pulse width, ignition timing advance and vehicle speed control operation. The center terminal of the park/neutral position switch is the starter-circuit terminal. It provides the ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. The outer terminals on the switch are for the backup lamp circuit. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2479 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for speed control system operation. For the location of the transmission output shaft sensor, please refer to Transmission Speed Sensor/Locations. See: Transmission Control Systems/Sensors and Switches - Transmission and Drivetrain/Sensors and Switches - A/T/Transmission Speed Sensor For the location of the rear wheel speed sensor, please refer to Brakes and Traction Control/Brakes/Antilock Brake System/Wheel Speed Sensor/Locations. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2485 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2486 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2487 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2488 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2489 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2490 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2491 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2492 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2493 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2494 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2495 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2496 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2497 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2498 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2499 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2500 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2501 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2502 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2503 Vehicle Speed Sensor: Description and Operation VEHICLE SPEED AND DISTANCE-PCM INPUT Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for fuel system and speed control system operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Description and Operation Voltage Signal: Description and Operation BATTERY VOLTAGE-PCM INPUT The battery voltage input provides power to the Powertrain Control Module (PCM). It also informs the PCM what voltage level is supplied to the ignition coil and fuel injectors. If battery voltage is low, the PCM will increase injector pulse width (period of time that the injector is energized). This is done to compensate for the reduced flow through injector caused by the lowered voltage. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation The stainless steel catalytic converter body is designed to last the life of the vehicle. Excessive heat can result in bulging or other distortion, but excessive heat will not be the fault of the converter. If unburned fuel enters the converter, overheating may occur. If a converter is heat-damaged, correct the cause of the damage at the same time the converter is replaced. Also, inspect all other components of the exhaust system for heat damage. Unleaded gasoline must be used to avoid contaminating the catalyst core. DO NOT remove spark plug wires from plugs or by any other means short out cylinders. Failure of the catalytic converter can occur due to a temperature increase caused by unburned fuel passing through the converter. DO NOT allow the engine to operate at fast idle for extended periods (over 5 minutes). This condition may result in excessive temperatures in the exhaust system and on the floor pan. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 2511 Catalytic Converter: Service and Repair 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. REMOVAL 1. Disconnect battery negative cable. 2. Remove passenger front seat track left rear mounting bolt (4X4 vehicles only). 3. Raise vehicle on hoist. 4. Remove tailpipe from rear hanger isolators. 5. Remove muffler to catalytic converter exhaust clamp. 6. Heat connection with an oxygen/acetylene torch and separate muffler from catalytic converter. 7. Disconnect catalytic converter rear hanger from isolators. 8. Disconnect downstream oxygen sensor. Catalytic Converter Removal/Installation 9. Remove catalytic converter to exhaust pipe clamp. 10. Heat connection with oxygen/acetylene and separate muffler from catalytic converter. 11. If equipped, remove front axle propeller shaft. Refer to Transmission and Drivetrain, Transfer Case for the correct procedure. 12. Disconnect upstream oxygen sensor. 13. Remove upper exhaust pipe to manifold bolts (one from each side) and allow exhaust pipe to hang. 14. Support transmission/transfer case with a stand and remove the transmission mount to crossmember nuts. 15. Remove transmission crossmember to frame bolts and move crossmember as far rearward (towards torsion bar crossmember) as possible. 16. Remove catalytic converter rear hanger. 17. Slide converter forward and out of vehicle. INSTALLATION 1. If the converter is being replaced, transfer oxygen sensor from old converter and tighten to 30 Nm (22 inch lbs.). 2. Install catalytic converter into place. 3. Slide transmission crossmember into place and tighten crossmember mounting bolts to 47 Nm (35 ft. lbs.). 4. Lower transmission/transfer case into place and remove stand. 5. Install and tighten transmission mount nuts to 47 Nm (35 ft. lbs.). 6. Install the converter hanger bracket and tighten bolts to 23 Nm (200 inch lbs.). 7. Install the two exhaust pipe to manifold bolts and tighten by hand. 8. Install catalytic converter to exhaust pipe with a new exhaust clamp. Start nuts by hand. 9. Install catalytic converter into hanger isolators. 10. Install muffler onto catalytic converter with a new clamp. Tighten nuts by hand. 11. If equipped, install front axle propeller shaft 12. Install muffler into rear hanger isolators. 13. Install tailpipe hanger into isolator. 14. Inspect exhaust system for contact with body or drivetrain components. Align as necessary. 15. Tighten exhaust pipe to manifold bolts to 34 Nm (25 ft. lbs.). 16. Tighten converter to exhaust pipe clamp to 43 Nm (32 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 2512 17. Tighten muffler to converter clamp to 43 Nm (32 ft. lbs.). 18. Lower vehicle. 19. Install passenger front seat track left rear mounting bolt (4X4 vehicles only). 20. Connect battery negative cable. 21. Start engine and check for exhaust leaks. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Bolts 11 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 2517 Canister Purge Solenoid: Locations Duty Cycle EVAP Purge Solenoid Location The solenoid attaches to a bracket located at the left-rear side of the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 2518 Duty Cycle Evap/Purge Solenoid Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 2519 Canister Purge Solenoid: Description and Operation A duty cycle EVAP canister purge solenoid is used. The solenoid regulates the rate of vapor flow from the EVAP canister to the intake manifold. The 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. Duty Cycle EVAP Purge Solenoid Location The solenoid attaches to a bracket located at the left-rear side of the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 2520 Canister Purge Solenoid: Service and Repair Duty Cycle Evap Canister Purge Solenoid The duty cycle EVAP canister purge solenoid is located at the left-rear side of engine compartment near power brake vacuum unit. REMOVAL 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 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 2524 Evaporative Emission Control Canister: Locations EVAP Canister Location The EVAP canister is located under the vehicle, inside the left frame rail, in front of the fuel tank. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 2525 Evaporative Emission Control Canister: Description and Operation 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 2526 Evaporative Emission Control Canister: Service and Repair EVAP Canister Location The EVAP canister is located below the vehicle, inside the left frame rail, in front of the fuel tank. REMOVAL 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 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Locations EVAP System Components Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > EVAP System - Leak Detection Pump Misdiagnosis Leak Detection Pump: Technical Service Bulletins EVAP System - Leak Detection Pump Misdiagnosis NUMBER: 18-01-00 GROUP: Vehicle Performance DATE: Feb. 4, 2000 SUBJECT: Misdiagnosed Leak Detection Pump Systems With DTC P1494, P0442, P0455, OR P0456 MODELS: 1997 - 2000 (AB) Ram Van 1997 - 2000 (AN) Dakota 1997 - 2000 (BR/BE) Ram truck 1998 - 2000 (DN) Durango 1997 - 2000 (FJ) Avenger/Sebring/Talon 1997 - 2000 (JA) Cirrus/Stratus/Breeze 1997 - 2000 (JX) Sebring Convertible 1997 - 2000 (LH) Concorde/Intrepid/LHS/3OOMNision 1997 - 2000 (NS) Town & Country/CaravanNoyager 1997 2000 (PL) Neon 1997 - 2000 (PR) Prowler 1997 - 2000 (SR) ViperNiper GIS 1997 - 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1997 - 2000 (XJ) Cherokee 1997 - 1998 (ZJ) GrandCherokee DISCUSSION: During evaporative system diagnosis, Leak Detection Pumps have mistakenly been replaced. A thorough inspection for pinched, kinked, or disconnected supply vacuum lines (as currently listed in the Powertrain Diagnostic Procedures) is a critical step in diagnosing DTC P1494 (LDP SW OR MECHANICAL FAULT). Additionally, the other evaporative leak faults (DTC P0442 SMALL LEAK, P0455 - LARGE LEAK, and P0456 - VERY SMALL LEAK) should have the supply vacuum lines examined for pinches or kinks prior to any LDP component replacement. The supply vacuum lines should be checked from the engine compartment all the way to the fuel tank, including the LDP and purge system. NOTE: VERIFY ALL RELATED SUPPLY VACUUM LINE ROUTINGS FOR PINCHES, KINKS, OR DISCONNECTION'S BEFORE REPLACING LDP SYSTEM COMPONENTS. POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2534 Leak Detection Pump: Specifications Leak Detection Pump (LDP) Mounting screws 1 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2535 Leak Detection Pump: Locations Leak Detection Pump(LDP) Location The LDP is located in the engine compartment under the battery tray and Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2536 Leak Detection Pump (LDP) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2537 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2538 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2539 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2540 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2541 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2542 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2543 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2544 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2545 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2546 Leak Detection Pump: Service and Repair Leak Detection Pump(LDP) Location 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. REMOVAL 1. Disconnect negative battery cable at battery. 2. Remove battery. Refer to Battery for procedures. 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. Refer to Battery for procedures. 8. Carefully remove vapor/vacuum lines at LDP 9. Disconnect electrical connector at LDP. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2547 Leak Detection Pump(LDP) Mounting Screws 10. Remove 3 LDP mounting screws and remove LDP from vehicle. INSTALLATION 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. Refer to Battery for procedures. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications EGR Tube: Specifications EGR Tube Bolts 200 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Testing and Inspection Positive Crankcase Ventilation Valve: Testing and Inspection Vacuum Check At PCV Valve - Typical 1. With engine idling, remove the PCV valve from cylinder head (valve) cover. If the valve is not plugged, a hissing noise will be heard as air passes through the valve. Also, a strong vacuum should be felt at the valve inlet. Vacuum Check At Valve Cover Opening 2. Return the PCV valve into the valve cover. Remove the fitting and air hose at the opposite valve cover. Loosely hold a piece of stiff paper, such as a parts tag, over the opening (rubber grommet) at the valve cover. 3. The paper should be drawn against the opening in the valve cover with noticeable force. This will be after allowing approximately one minute for crankcase pressure to reduce. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Testing and Inspection > Page 2556 Shake PCV Valve-Typical 4. Turn engine off and remove PCV valve from valve cover. The valve should rattle when shaken. 5. Replace the PCV valve and retest the system if it does not operate as described in the preceding tests. Do not attempt to clean the old PCV valve. 6. If the paper is not held against the opening in valve cover after new valve is installed, the PCV valve hose may be restricted and must be replaced. The passage in the intake manifold must also be checked and cleaned. 7. To clean the intake manifold fitting, turn 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Testing Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Use following procedure if fuel rail is or is not equipped with fuel pressure test port. 1. Remove fuel fill cap. 2. The fuel filler tube contains a spring-loaded flap (door) located below fuel fill cap. The flap is used as a secondary way of sealing fuel tank if fuel fill cap has not been properly tightened. It is part of EVAP monitor system when vehicle is equipped with a Leak Detection Pump (LDP). The vehicle may be equipped with flap installed into fuel filler tube even though vehicle is not equipped with LDP and EVAP monitor system. Place a nonmetallic object into fuel fill tube and press on flap to relieve any tank pressure. 3. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. 6. 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. 7. Unplug connector from any injector. 8. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 9. Connect other end of jumper wire to positive side of battery. 10. 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. 11. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 12. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 13. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 14. Return fuel pump relay to PDC. 15. 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. Refer to Emission Control System. See On-Board Diagnostics. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle ......................................................................................................................... ......................................................... 500 to 900 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 2568 Idle Speed: Testing and Inspection The following test procedure has been developed to check throttle body calibrations for correct idle conditions. The procedure should be used to diagnose the throttle body for conditions that may cause idle problems. This procedure should be used only after normal diagnostic procedures have failed to produce results that indicate a throttle body related problem. Be sure to check for proper operation of the idle air control motor before performing this test. Fixed Orifice Tool A special fixed orifice tool (number 6714) must be used for the following test. 1. Start the engine and bring to operating temperature. Be sure all accessories are off before performing this test. 2. Shut off the engine and remove the air duct at throttle body. Install Orifice Tool 3. Disconnect the vacuum line at the PCV valve. 4. Install the 0.185 inch orifice tool (number 6714) into the disconnected vacuum line in place of the PCV valve. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 2569 Idle Purge Line 5. Disconnect the idle purge vacuum line from fitting at throttle body. This vacuum line is located on the front of throttle body next to the MAP sensor. Cap the fitting at throttle body after vacuum line has been removed. 6. Connect the DRB scan tool to the 16-way data link connector. This connector is located under the instrument panel to the left of the steering column. Refer to the appropriate Powertrain Diagnostic Procedures service for DRB operation. 7. Start the engine and allow to warm up. 8. Using the DRB scan tool, scroll through the menus as follows: select-Stand Alone DRB III, select 1999 Diagnostics, select-Engine, select-System Test, select-Minimum Air Flow. 9. The DRB scan tool will count down to stabilize the idle rpm and display the minimum air flow idle rpm. The idle rpm should be between 500 and 900 rpm. If the idle speed is outside of these specifications, replace the throttle body. Refer to Throttle Body in the Component Removal/Installation. 10. Disconnect the DRB scan tool from the vehicle. 11. Remove cap from idle purge fitting at throttle body and install vacuum line. 12. Remove orifice tool and connect vacuum line to PCV valve. 13. Install air duct to throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 2573 Accelerator Pedal: Service and Repair All engines are equipped with torsion return springs located on the throttle body shaft. All 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. REMOVAL 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. Plastic cable retainer snaps into pedal arm. 2. Remove two accelerator pedal/bracket nuts and remove pedal/bracket assembly from vehicle. INSTALLATION 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. 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 2574 pedal arm. Align the index slot on the plastic cable retainer to this index tab. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Air Cleaner Housing Assembly 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 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications Fuel: Specifications Fuel Rating Fuel Rating Fuel Unleaded fuel having a minimum octane rating of 87. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications > Page 2582 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation Fuel Filler Cap: Description and Operation The loss of any fuel or vapor out of filler neck is prevented by the use of a pressure-vacuum fuel tank filler tube 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 fuel tank filler tube cap before servicing any fuel system component. This is done to help relieve tank pressure. If equipped with a California emissions package and a Leak Detection Pump (LDP), the secondary seal below the fill cap must be pressed (opened) to relieve fuel tank pressure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Page 2586 Fuel Filler Cap: Service and Repair If replacement of the 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Use following procedure if fuel rail is or is not equipped with fuel pressure test port. 1. Remove fuel fill cap. 2. The fuel filler tube contains a spring-loaded flap (door) located below fuel fill cap. The flap is used as a secondary way of sealing fuel tank if fuel fill cap has not been properly tightened. It is part of EVAP monitor system when vehicle is equipped with a Leak Detection Pump (LDP). The vehicle may be equipped with flap installed into fuel filler tube even though vehicle is not equipped with LDP and EVAP monitor system. Place a nonmetallic object into fuel fill tube and press on flap to relieve any tank pressure. 3. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. 6. 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. 7. Unplug connector from any injector. 8. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 9. Connect other end of jumper wire to positive side of battery. 10. 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. 11. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 12. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 13. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 14. Return fuel pump relay to PDC. 15. 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. Refer to Emission Control System. See On-Board Diagnostics. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Hose Clamp > Component Information > Specifications > Page 2594 Fuel Hose Clamp: 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Hose Clamp > Component Information > Specifications > Page 2595 Fuel Hose Clamp: Service and Repair 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. Inspect all hose connections such as clamps, couplings and fittings to make sure they are secure and leaks are not present. The component should be replaced immediately if there is any evidence of degradation that could result in failure. Never attempt to repair a plastic fuel line/tube. Replace as necessary. Avoid contact of any fuel tubes/hoses with other vehicle components that could cause abrasions or scuffing. Be sure that the plastic fuel lines/tubes are properly routed to prevent pinching and to avoid heat sources. 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. Tighten hose clamps to 3 Nm (25 in. lbs.) torque. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications Injector Resistance ...................................................................................................................................................... 12 ohms ± 1.2 ohms at 20 ° C (68 ° F) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 2600 Fuel Injector: Pressure, Vacuum and Temperature Specifications Use this test in conjunction with the Fuel Pump Pressure Test and Fuel Pump Capacity Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately (1-2 seconds) rise to specification. Abnormally long periods of cranking to restart a hot engine that has been shut down for a short period of time may be caused by: - Fuel pressure bleeding past a fuel injector(s). - Fuel pressure bleeding past the check valve in the fuel pump module. 1. Disconnect the fuel inlet line at fuel rail. Refer to Fuel Tubes/Lines/Hoses and Clamps for procedures. On some engines, air cleaner housing removal may be necessary before fuel line disconnection. 2. Obtain correct Fuel Line Pressure Test Adapter Tool Hose. Tool number 6539 is used for 5/16" fuel lines and tool number 6631 is used for 3/8" fuel lines. Connecting Adaptor Tool - Typical Connecting Adaptor Tool - Typical 3. Connect correct Fuel Line Pressure Test Adapter Tool Hose between disconnected fuel line and fuel rail. 4. Connect the 0-414 kPa (0-60 psi) fuel pressure test gauge (from Gauge Set 5069) to the test port on the appropriate Adaptor Tool. The fittings on both tools must be in good condition and free from any small leaks before performing the proceeding test. 5. Start engine and bring to normal operating temperature. 6. Observe test gauge. Normal operating pressure should be 339 kPa ± 34 kPa (49.2 psi ± 5 psi). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 2601 7. Shut engine off 8. Pressure should not fall below 30 psi for five minutes. 9. If pressure falls below 30 psi, it must be determined if a fuel injector, the check valve within the fuel pump module, or a fuel tube/line is leaking. 10. Again, start engine and bring to normal operating temperature. 11. Shut engine off. 12. Testing for fuel injector or fuel rail leakage: Clamp off the rubber hose portion of Adaptor Tool between the fuel rail and the test port "T" on Adapter Tool. If pressure now holds at or above 30 psi, a fuel injector or the fuel rail is leaking. 13. Testing for fuel pump check valve, filter regulator check valve or fuel tube/line leakage: Clamp off the rubber hose portion of Adaptor Tool between the vehicle fuel line and test port "T" on Adapter Tool. If pressure now holds at or above 30 psi, a leak may be found at a fuel tube/line. If no leaks are found at fuel tubes or lines, one of the check valves in either the electric fuel pump or filter/ regulator may be leaking. Note: A quick loss of pressure usually indicates a defective check valve in the filter/regulator. A slow loss of pressure usually indicates a defective check valve in the electric fuel pump. The electric fuel pump is not serviced separately. Replace the fuel pump module assembly. The filter regulator may be replaced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2602 Fuel Injector: Locations Fuel Injectors The fuel injectors are attached to the fuel rail Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2603 Fuel Injector: Diagrams Fuel Injector No. 1 Fuel Injector No. 2 Fuel Injector No. 3 Fuel Injector No. 4 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2604 Fuel Injector No. 5 Fuel Injector No. 6 Fuel Injector No. 7 (5.2/5.9) Fuel Injector No. 8 (5.2/5.9) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2605 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2606 Fuel Injector: Description and Operation Fuel Injector-Typical FUEL INJECTORS 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. An individual fuel injector is used for each individual cylinder. The top (fuel entry) end of the injector is attached into an opening on the fuel rail. 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. During start up, battery voltage is supplied to the injectors through the ASD relay. When the engine is operating, voltage is supplied by the charging system. The PCM determines injector pulse width based on various inputs. Fuel Injectors FUEL INJECTORS- PCM OUTPUT The fuel injectors are attached to the fuel rail. These engines use eight injectors. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2607 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. During start up, battery voltage is supplied to the injectors through the ASD relay. When the engine is operating, voltage is supplied by the charging system. The PCM determines injector pulse width based on various inputs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2608 Fuel Injector: Testing and Inspection Fuel Injector Internal Components - Typical To perform a complete test of the fuel injectors and their circuitry, refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the injector only, refer to the following: Disconnect the fuel injector wire harness connector from the injector. Place an ohmmeter across the injector electrical terminals. Resistance reading should be approximately 12 ohms ± 1.2 ohms at 20° C (68° F). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2609 Fuel Injector: Service and Repair 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. REMOVAL 1. Remove air cleaner assembly. 2. Remove fuel injector rail assembly. Refer to Fuel Injector Rail Removal/Installation. Fuel Injector Mounting - Typical Injector Retaining Clips - Typical Injector 3. Remove clip(s) retaining the injector(s) to fuel rail. 4. Remove injector(s) from fuel rail. INSTALLATION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions Fuel Line Coupler: 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. CAUTION: The interior components (O-rings, spacers, retainers) of this type of quick-connect fitting are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Page 2613 Fuel Line Coupler: Description and Operation QUICK-CONNECT FITTINGS Different types of quick-connect fittings are used to attach various fuel system components. These are: a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. Refer to the Removal/installation for more information. CAUTION: The interior components (O-rings, spacers) of quick-connect fitting are not serviced separately, but new pull tabs are available for some types. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Page 2614 Fuel Line Coupler: Service and Repair Different types of quick-connect fittings are used to attach various fuel system components. These are: a single-tab type, a two-tab type, a plastic retainer ring type or a latch clip type. Certain fittings may require the use of a special tool for disconnection. SINGLE-TAB TYPE Single-Tab Type Fitting This type of fitting is equipped with a single pull tab. The tab is removable. After the tab is removed, the quick-connect fitting can be separated from the fuel system component. CAUTION: The interior components (O-rings, spacers) of this type of quick-connect fitting are not serviced separately, but new pull tabs are available. Do not attempt to repair damaged fittings or fuel lines tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Disconnection/Connection 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. Disconnecting Single-tab Type Fitting 4. Press release tab on side of fitting to release pull tab. CAUTION: If this release tab is not pressed prior to releasing the pull tab, the pull tab will be damaged. 5. While pressing release tab on side of fitting, use a screwdriver to pry up pull tab. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Page 2615 Removing Pull Tab 6. Raise pull tab until it separates from quick-connect fitting. Discard old pull tab. 7. Disconnect quick-connect fitting from fuel system component being serviced. 8. Inspect quick-connect fitting body and fuel system component for damage. Replace as necessary. 9. 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. 10. 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. 11. Obtain a new pull tab. Push new tab down until it locks into place in quick-connect fitting. 12. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 13. Connect negative cable to battery. 14. Start engine and check for leaks. Typical Two-Tab Type Quick-connect Fitting TWO-TAB TYPE FITTING This type of fitting is equipped with tabs located on both sides of the fitting. These tabs are supplied for disconnecting the quick-connect fitting from component being serviced. CAUTION: The interior components (O-rings, spacers) of this type of quick-connect fitting are not serviced separately, but new plastic retainers are available. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE. Disconnection/Connection 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. 4. To disconnect quick-connect fitting, squeeze plastic retainer tabs against sides of quick-connect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. Pull fitting from fuel system component being serviced. 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. 5. Inspect quick-connect fitting body and component for damage. Replace as necessary. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Page 2616 CAUTION: When the quick-connect fitting was disconnected, the plastic retainer will remain on the component being serviced. If this retainer must be removed, very carefully release the retainer from the component with two small screwdrivers. After removal, inspect the retainer for cracks or any damage. 6. Prior to connecting 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. 7. Insert quick-connect fitting to component being serviced and into plastic retainer. When a connection is made, a click will be heard. 8. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 9. Connect negative cable to battery. 10. Start engine and check for leaks. Plastic Retainer Ring Type Fitting PLASTIC RETAINER RING TYPE FITTING This type of fitting can be identified by the use of a full-round plastic retainer ring usually black in color. CAUTION: The interior components (O-rings, spacers, retainers) of this type of quick-connect fitting are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Disconnection/Connection 1. 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. 4. To release fuel system component from quick- connect fitting, firmly push fitting towards component being serviced while firmly pushing plastic retainer ring into fitting. With plastic ring depressed, pull fitting from component. The plastic retainer ring must be pressed 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. 5. After disconnection, plastic retainer ring will remain with quick-connect fitting connector body. 6. Inspect fitting connector body, plastic retainer ring and fuel system component for damage. Replace as necessary. 7. Prior to connecting 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. 8. Insert quick-connect fitting into component being serviced until a click is felt. 9. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 10. Connect negative battery cable to battery. 11. Start engine and check for leaks. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Page 2617 Latch Clip Removal LATCH CLIP FITTING (FUEL LINE-TO-FUEL RAIL) A tethered latch clip is used to secure the fuel line to the fuel rail. A special tool will be necessary to separate fuel line from fuel rail after latch clip is removed. This same latch clip may also be used to secure other different fuel system components. CAUTION: The interior components (O-rings, spacers, retainers) of this type of quick-connect fitting are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Disconnection/Connection 1. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure. 1. Disconnect negative battery cable from battery. 3. Clean fitting of any foreign material before disassembly. 4. Pry up on latch clip with a screwdriver. 5. Slide latch clip toward fuel rail while lifting with screwdriver. Fuel Line Disconnection 6. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into fuel line. Use this tool to release locking fingers in end of line. 7. With special tool still inserted, pull fuel line from fuel rail. 8. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line. 9. Prior to connecting fuel line to fuel rail, check condition of both fittings. Clean parts with a lint-free cloth. Lubricate with clean engine oil. 10. Insert fuel line onto fuel rail until a click is felt. 11. Install latch clip (snaps into position). If latch clip will not fit, this indicates fuel line is not properly installed to fuel rail. Recheck fuel line connection. 12. Verify a locked condition by firmly pulling on fuel line and fitting (15-30 lbs.). 13. Connect negative battery cable to battery. 14. Start engine and check for leaks. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations Fuel Pressure Regulator: Locations Side View - Filter/Regulator Fuel Fill/Vent Tube Assembly, Rollover Valve, Fuel Pump Module, Fuel Tank, Fuel Filter/Fuel Pressure Regulator It is located on the top of the fuel pump module. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2621 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2622 Fuel Pressure Regulator: Description and Operation Side View - Filter/Regulator FUEL FILTER/FUEL PRESSURE REGULATOR A combination fuel filter and fuel pressure regulator 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 is also part of the assembly. Fuel is supplied to the filter/regulator by the electric fuel pump through an opening tube at the bottom of filter/regulator. The 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. FUEL PUMP MODULE Fuel Pump Module/Fuel Tank (Top View) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2623 Fuel Pump Module Components (Typical Pump Module Shown) The fuel pump module on all models/all engines is installed in the top of the fuel tank. The fuel pump module contains the following components. A combination fuel filter/fuel pressure regulator - Electric fuel pump - Fuel pump reservoir - A separate in-tank fuel filter (at bottom of module) - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection at filter/regulator - A metal lock-ring to retain pump module to fuel tank - A gasket between tank flange and module The fuel gauge sending unit (fuel level sensor), and pick-up filter (at bottom of module) may be serviced separately. If the electrical fuel pump requires service, the entire fuel pump module must be replaced. The fuel filter/fuel pressure regulator may be serviced separately. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair > Fuel Filter/Fuel Pressure Regulator Replacement Fuel Pressure Regulator: Service and Repair Fuel Filter/Fuel Pressure Regulator Replacement Fuel Filter/Fuel Pressure Regulator 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. Filter/Regulator Location Refer to Fuel System Pressure Release in the Fuel Delivery System. The fuel filter/fuel pressure regulator is located at top of fuel pump module on top of fuel tank. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair > Fuel Filter/Fuel Pressure Regulator Replacement > Page 2626 Fuel Tube And Clamp-TYPICAL 4. Gently cut old fuel tube (line) clamp 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. Tightening Fuel Filter Tube Clamp-TYPICAL 2. Install filter/regulator to fuel tube. Rotate filter/regulator in fuel tube (line) 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. 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. 6. Install fuel tank. Refer to Fuel Tank Removal/ Installation. 7. Check for fuel leaks. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair > Fuel Filter/Fuel Pressure Regulator Replacement > Page 2627 Fuel Pressure Regulator: Service and Repair Fuel Pump Module Replacement REMOVAL WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING FUEL PUMP MODULE, FUEL SYSTEM PRESSURE MUST BE RELEASED. The fuel pump module is located in top of fuel tank. 1. Drain fuel tank and remove tank. Refer to Fuel Tank Removal/lnstallation. 2. Thoroughly wash and clean area around pump module to prevent contaminants from entering tank. Fuel Pump Module And Locking 3. Part of Fuel Tank Removal Procedure: Disconnect EVAP line at pump module; disconnect wiring harness connector at pump module; disconnect fuel line from fuel filter fitting. 4. Rotate fuel filter until its fitting is pointed towards center of pump module. 5. A metal lockring is used to secure fuel pump module to fuel tank. Six metal fingers are molded into the plastic fuel tank. The fingers are used to retain lockring to fuel tank. A rubber gasket is used as a seal between module and fuel tank. 6. Before removing lockring, apply a small amount of engine oil to 6 fingers where fingers meet lockring (to act as a lubricant). 7. Remove (rotate) lockring counterclockwise using a brass or bronze drift punch and a hammer. This must be done while slightly prying back on lock tab. 8. Remove lockring and pump module from fuel tank. INSTALLATION CAUTION: Whenever fuel pump module is serviced, the module gasket must be replaced. 1. Using a new gasket, position fuel pump module into opening in fuel tank. Be sure rubber gasket remains in place. Rotate pump module assembly until module is positioned as shown in. This step must be followed to prevent float/float rod from contacting sides of fuel tank. 2. Before installing lockring, apply a small amount of engine oil to 6 fingers where fingers meet lockring (to act as a lubricant). 3. Position lockring over top of fuel pump module. Tighten finger tight. 4. Install (rotate) lockring clockwise using a brass or bronze drift punch and a hammer. Continue rotating lockring until 6 fingers drop into 6 finger locks and lock tab falls into lockring notch. 5. Install fuel tank. Refer to Fuel Tank Installation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Testing Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Testing Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distributor Center (PDC) Location Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2639 Power Distribution Center The fuel pump relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2640 Fuel Pump Relay: Diagrams Power Distribution Center Fuel Pump Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2641 Fuel Pump Relay: Description and Operation FUEL PUMP RELAY-PCM OUTPUT The PCM energizes the electric fuel pump through the fuel pump relay. Battery voltage is applied to the fuel pump relay when the ignition key is ON. The relay is energized when a ground signal is provided by the PCM. The fuel pump will operate for approximately one second unless the engine is operating or the starter motor is engaged. The fuel pump relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2642 Fuel Pump Relay: Testing and Inspection ASD And Fuel Pump Relay Terminals 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. Operation 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. Testing The following procedure applies to the ASD and fuel pump relays. 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 ± 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 source5 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2643 Fuel Pump Relay: Service and Repair Power Distributor Center (PDC) Location The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. REMOVAL 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 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Locations Fuel Pump Pickup Filter: Locations Fuel Pump Inlet Filter The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Locations > Page 2647 Fuel Pump Pickup Filter: Description and Operation FUEL PUMP MODULE Fuel Pump Module/Fuel Tank (Top View) Fuel Pump Module Components (Typical Pump Module Shown) The fuel pump module on all models/all engines is installed in the top of the fuel tank. The fuel pump module contains the following components. A combination fuel filter/fuel pressure regulator - Electric fuel pump - Fuel pump reservoir - A separate in-tank fuel filter (at bottom of module) - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection at filter/regulator - A metal lock-ring to retain pump module to fuel tank - A gasket between tank flange and module The fuel gauge sending unit (fuel level sensor), and pick-up filter (at bottom of module) may be serviced separately. If the electrical fuel pump requires service, the entire fuel pump module must be replaced. The fuel filter/fuel pressure regulator may be serviced separately. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Service and Repair > Fuel Pump Inlet Filter Replacement Fuel Pump Pickup Filter: Service and Repair Fuel Pump Inlet Filter Replacement Fuel Pump Inlet Filter 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. REMOVAL 1. Remove fuel tank. Refer to Fuel Tank Removal/ Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/installation, 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 1. Snap new filter to bottom of module. Be sure O-ring is in correct position. 2. Install fuel pump module. Refer to Fuel Pump Module Removal/installation. 3. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Service and Repair > Fuel Pump Inlet Filter Replacement > Page 2650 Fuel Pump Pickup Filter: Service and Repair Fuel Pump Module Replacement REMOVAL WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING FUEL PUMP MODULE, FUEL SYSTEM PRESSURE MUST BE RELEASED. The fuel pump module is located in top of fuel tank. 1. Drain fuel tank and remove tank. Refer to Fuel Tank Removal/lnstallation. 2. Thoroughly wash and clean area around pump module to prevent contaminants from entering tank. Fuel Pump Module And Locking 3. Part of Fuel Tank Removal Procedure: Disconnect EVAP line at pump module; disconnect wiring harness connector at pump module; disconnect fuel line from fuel filter fitting. 4. Rotate fuel filter until its fitting is pointed towards center of pump module. 5. A metal lockring is used to secure fuel pump module to fuel tank. Six metal fingers are molded into the plastic fuel tank. The fingers are used to retain lockring to fuel tank. A rubber gasket is used as a seal between module and fuel tank. 6. Before removing lockring, apply a small amount of engine oil to 6 fingers where fingers meet lockring (to act as a lubricant). 7. Remove (rotate) lockring counterclockwise using a brass or bronze drift punch and a hammer. This must be done while slightly prying back on lock tab. 8. Remove lockring and pump module from fuel tank. INSTALLATION CAUTION: Whenever fuel pump module is serviced, the module gasket must be replaced. 1. Using a new gasket, position fuel pump module into opening in fuel tank. Be sure rubber gasket remains in place. Rotate pump module assembly until module is positioned as shown in. This step must be followed to prevent float/float rod from contacting sides of fuel tank. 2. Before installing lockring, apply a small amount of engine oil to 6 fingers where fingers meet lockring (to act as a lubricant). 3. Position lockring over top of fuel pump module. Tighten finger tight. 4. Install (rotate) lockring clockwise using a brass or bronze drift punch and a hammer. Continue rotating lockring until 6 fingers drop into 6 finger locks and lock tab falls into lockring notch. 5. Install fuel tank. Refer to Fuel Tank Installation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications Fuel Rail: Specifications Fuel Rail Mounting Bolts 23 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 2654 Fuel Rail: Locations Fuel Rail The fuel rail is mounted to the intake manifold. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 2655 Fuel Rail: Description and Operation Fuel Rail The fuel rail supplies the necessary fuel to each individual fuel injector and is mounted to the intake manifold. The fuel pressure regulator is not mounted to the fuel rail on any engine. It is located on the fuel tank mounted fuel pump module. Refer to Fuel Filter/Fuel Pressure Regulator for information. The fuel rail is not repairable. CAUTION: The left and right sections of the fuel rail are connected with a flexible connecting hose. Do not attempt to separate the rail halves at this connecting hose. Due to the design of this connecting hose, it does not use any clamps. Never attempt to install a clamping device of any kind to the hose. When removing the fuel rail assembly for any reason, be careful not to bend or kink the connecting hose. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 2656 Fuel Rail: Service and Repair 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. To release fuel pressure, refer to Fuel System Pressure Release Procedure. Fuel Rail Assembly CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate rail halves at connecting hose. Due to the design of this connecting hose, it does not use any clamps. Never attempt to install a clamping device of any kind to hose. When removing fuel rail assembly for any reason, be careful not to bend or kink connecting hose. REMOVAL 1. Remove negative battery cable at battery. 2. Remove air cleaner. 3. Perform fuel pressure release procedure. 4. Remove throttle body from intake manifold. Refer to Throttle Body removal. A/C Compressor Support Bracket - Typical 5. If equipped with air conditioning, remove A-shaped A/C compressor-to-intake manifold support bracket (three bolts). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 2657 Fuel Injector Connectors - Typical 6. Disconnect electrical connectors at all fuel injectors. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. 7. Disconnect fuel tube (line) at side of fuel rail. Refer to Quick-Connect Fittings for procedures, 8. Remove remaining fuel rail mounting bolts. 9. Clean dirt/debris from each fuel injector at intake manifold. 10. Gently rock and pull left fuel rail until fuel injectors just start to clear intake manifold. Gently rock and pull right fuel rail until fuel injectors just start to clear intake manifold. Repeat this procedure (left/right) until all fuel injectors have cleared intake manifold. 11. Remove fuel rail (with injectors attached) from engine. Fuel Injector Mounting - Typical Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 2658 Injector Retaining Clips - Typical Injector 12. Remove clip(s) retaining injector(s) to fuel rail. INSTALLATION 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. Position fuel rail/fuel injector assembly to injector openings on intake manifold. 4. Guide each injector into intake manifold. Be careful not to tear injector O-ring. 5. Push right fuel rail down until fuel injectors have bottomed on injector shoulder. Push left fuel rail down until fuel injectors have bottomed on injector shoulder. 6. Install fuel rail mounting bolts. 7. Connect electrical connector to intake manifold air temperature sensor. 8. Connect wiring to all fuel injectors. The injector wiring harness is numerically tagged. 9. Install A/C support bracket (if equipped). 10. Install throttle body to intake manifold. Refer to Throttle Body installation. 11. Install fuel tube (line) at side of fuel rail. Refer to Quick-Connect Fittings for procedures. 12. Install air cleaner. 13. Connect battery cable to battery. 14. Start engine and check for leaks. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Component Locations Fuel Gauge Sender: Component Locations 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Component Locations > Page 2664 Fuel Fill/Vent Tube Assembly, Rollover Valve, Fuel Pump Module, Fuel Tank, Fuel Filter/Fuel Pressure Regulator Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 2665 Fuel Pump Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 2666 Fuel Gauge Sender: Description and Operation Fuel Pump Module/Fuel Tank (Top View) Fuel Pump Module Components (Typical Pump Module Shown) FUEL PUMP MODULE The fuel pump module on all models/all engines is installed in the top of the fuel tank. The fuel pump module contains the following components. A combination fuel filter/fuel pressure regulator Electric fuel pump - Fuel pump reservoir - A separate in-tank fuel filter (at bottom of module) - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection at filter/regulator - A metal lock-ring to retain pump module to fuel tank - A gasket between tank flange and module The fuel gauge sending unit (fuel level sensor), and pick-up filter (at bottom of module) may be serviced separately. If the electrical fuel pump requires service, the entire fuel pump module must be replaced. The fuel filter/fuel pressure regulator may be serviced separately. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. FUEL GAUGE SENDING UNIT 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). The resistor track is used to send electrical signals to the Powertrain Control Module (PCM) for fuel gauge operation and for OBDII emission requirements. For fuel gauge operation: As fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge to read full. As fuel level decreases, the float and arm move down. This increases the sending unit resistance causing the fuel gauge to read empty. After this fuel level signal is sent to the PCM, the PCM will transmit the data across the CCD bus circuits to the instrument panel. Here it is translated into the appropriate fuel gauge level reading. For OBD II emission monitor requirements: A voltage signal is sent from the resistor track on the sending unit to the PCM to indicate fuel level. The purpose of this feature is to prevent the OBDII system from recording/setting false misfire and fuel system monitor 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 2667 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 2668 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 ohms. With float in down position, resistance should be 220 ohms ± 6 ohms. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Gauge Sending Unit Replacement Fuel Gauge Sender: Service and Repair Fuel Gauge Sending Unit Replacement 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. REMOVAL 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/installation. 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. Fuel Gauge Sending Unit Lock Tab/Tracks 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 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. Refer to Fuel Pump Module Removal/Installation. 6. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Gauge Sending Unit Replacement > Page 2671 Fuel Gauge Sender: Service and Repair Fuel Pump Module Replacement REMOVAL WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING FUEL PUMP MODULE, FUEL SYSTEM PRESSURE MUST BE RELEASED. The fuel pump module is located in top of fuel tank. 1. Drain fuel tank and remove tank. Refer to Fuel Tank Removal/lnstallation. 2. Thoroughly wash and clean area around pump module to prevent contaminants from entering tank. Fuel Pump Module And Locking 3. Part of Fuel Tank Removal Procedure: Disconnect EVAP line at pump module; disconnect wiring harness connector at pump module; disconnect fuel line from fuel filter fitting. 4. Rotate fuel filter until its fitting is pointed towards center of pump module. 5. A metal lockring is used to secure fuel pump module to fuel tank. Six metal fingers are molded into the plastic fuel tank. The fingers are used to retain lockring to fuel tank. A rubber gasket is used as a seal between module and fuel tank. 6. Before removing lockring, apply a small amount of engine oil to 6 fingers where fingers meet lockring (to act as a lubricant). 7. Remove (rotate) lockring counterclockwise using a brass or bronze drift punch and a hammer. This must be done while slightly prying back on lock tab. 8. Remove lockring and pump module from fuel tank. INSTALLATION CAUTION: Whenever fuel pump module is serviced, the module gasket must be replaced. 1. Using a new gasket, position fuel pump module into opening in fuel tank. Be sure rubber gasket remains in place. Rotate pump module assembly until module is positioned as shown in. This step must be followed to prevent float/float rod from contacting sides of fuel tank. 2. Before installing lockring, apply a small amount of engine oil to 6 fingers where fingers meet lockring (to act as a lubricant). 3. Position lockring over top of fuel pump module. Tighten finger tight. 4. Install (rotate) lockring clockwise using a brass or bronze drift punch and a hammer. Continue rotating lockring until 6 fingers drop into 6 finger locks and lock tab falls into lockring notch. 5. Install fuel tank. Refer to Fuel Tank Installation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > Recalls: > 842 > Feb > 00 > Recall - Fuel Tank Straps Fuel Tank Mounting Straps: Recalls Recall - Fuel Tank Straps NO 842 DATE 02/04/00 Safety Recall # 842 - Fuel Tank Straps February 2000 Dealer Service Instructions for: Models 1998-1999 (DN) Dodge Durango Dealers Service Instructions for: Safety Recall # 842 - Fuel Tank Straps NOTE: This recall applies only to the above vehicles built from May 22, 1998 through September 25, 1998 (MDH 0522XX through 0925XX) NOTE: Safety Recall No. 841 also involves fuel tank strap replacement but applies to earlier built vehicles that also require a brake tube inspection. RECALL MATERIAL ENCLOSED IMMEDIATE ACTION REQUIRED The envelope contains one copy of the dealer recall service instruction letter. In addition, a VIN listing is included for those dealers to whom involved vehicles were invoiced. THE OWNER NOTIFICATION MAILING FOR THIS RECALL WILL BEGIN IN ABOUT ONE WEEK. Please advise the appropriate dealer personnel to forward the orange bordered recall envelope to your service manager as soon as it is received. Doing so will insure that 'our dealership is ready to schedule and repair involved vehicles 3 soon as possible. Additional copies of the recall notification letter will be forwarded via DCMMS mail and the MDS2 in the near future. The entire dealer recall notification letter (excluding graphics) is provided below for your information. 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 DIAL VIP System. SUBJECT The fuel tank straps on about 55,000 of the above vehicles may fatigue and separate. If this occurs, the fuel tank will loosen and could leak fuel. Fuel leakage in the presence of an ignition source can result in an underbody fire. REPAIR The front and rear fuel tank straps must be replaced. Parts Information Part Number Description CBNF841O Fuel Tank Strap Package Each package contains the following components: Quantity Description 1 Fuel Tank Strap - Front 1 Fuel Tank Strap - Rear 1 Rubber Isolator NOTE: The rubber isolator that is included in the package is not used for this recall service procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > Recalls: > 842 > Feb > 00 > Recall - Fuel Tank Straps > Page 2680 Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Fuel Tank Strap Packages to service about 25% of those vehicles. SERVICE PROCEDURE 1. Raise the vehicle on an appropriate hoist. 2. For vehicles equipped with a fuel tank skid plate: a. Place a transmission jack under the fuel tank skid plate and support the skid plate. b. Remove the inboard screws that attach the skid plate to the frame crossmember. C. Remove the bolts that attach the skid plate to the frame rail . d. Lower the skid plate and remove it from under the vehicle. 3. Place a transmission jack under the fuel tank and support the fuel tank. 4. Remove the front tank strap mounting nut and remove the front tank strap. NOTE: Lower the fuel tank slightly to ease removal of the strap from the mounting hole. 5. Install the provided front tank strap. Tighten the strap mounting nut to 30 ft-lbs (41 Nm). 6. Remove the rear tank strap mounting nut and remove the rear tank strap. NOTE: Lower the fuel tank slightly to ease removal of the strap from the mounting hole. 7. Install the provided rear tank strap. Tighten the strap mounting nut to 30 ft-lbs (41 Nm). Remove the transmission jack. 9. For vehicles equipped with a fuel tank skid plate: a. Position the skid plate under the vehicle and support it with a transmission jack. b. Install the inboard screws that attach the skid plate to the frame crossmember. Tighten the screws to 30 ft-lbs (41 Nm) C. Install the bolts that attach the skid plate to the frame rail (Figure 1). Tighten the bolts to 17 ft-lbs (23 Nm) d. Remove the transmission jack. 10. Lower the vehicle. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time Allowances Add the cost of the recall parts package plus applicable dealer allowance to your claim. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > Recalls: > 842 > Feb > 00 > Recall - Fuel Tank Straps > Page 2681 NOTE: See the warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return: Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MD52 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Dial System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD842". 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 copy of the owner notification letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service1 let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > Recalls: > 841 > Feb > 00 > Recall - Fuel Tank Straps and Rear Brake Tube Fuel Tank Mounting Straps: Recalls Recall - Fuel Tank Straps and Rear Brake Tube NO 841 DATE 02/17/00 SAFETY RECALL 841 Fuel Tank Straps and Rear Brake Tube MODELS 1998 ,(DN) Dodge Durango ATTENTION: Service Manager RECALL MATERIAL ENCLOSED IMMEDIATE ACTION REQUIRED The envelope contains one copy of the dealer recall service instruction letter. In addition, a VIN listing is included for those dealers to whom involved vehicles were invoiced. The owner notification mailing for this recall will begin in about one week. Please advise the appropriate dealer personnel to forward the orange bordered recall envelope to your service manager as soon as it is received. Doing so will insure that our dealership is ready to schedule and repair involved vehicles soon as possible. Additional copies of the recall notification letter will be forwarded via DCMMS mail and the MDS2 in the near future. The entire dealer recall notification letter (excluding graphics) is provided below for your information. February 2000 Dealer Service Instructions for: SAFETY RECALL No. 841 FUEL TANK STRAPS AND REAR BRAKE TUBE. NOTE: This recall applies only to the above vehicles built through May 21, 1998 (MDH 0521XX). NOTE: Safety Recall No. 842 also involves fuel tank strap replacement but applies to later built vehicles that do not require the brake tube inspection. ATTENTION: Service Manager Recall material enclosed immediate action required require the brake tube inspection. 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 DIAL VIP System. SUBJECT The fuel tank straps on about 96,OOO of the above vehicles may fatigue and separate. If this occurs, the fuel tank will loosen and could leak fuel. Fuel leakage in the presence of an ignition source can result in an underbody fire. In addition, the rear brake tube may contact an underbody crossmember. Prolonged brake tube contact may cause the tube to rub through and leak, resulting in a partial brake system loss and increased stopping distance. The increased stopping distance can cause an accident without warning. REPAIR The front and rear fuel tank straps must be replaced, and the rear brake tube must be inspected on all involved vehicles. ~7ehicles without brake tube contact must have a brake tube isolator installed. Vehicles that exhibit contact but have no signs of red rust AND have less than 45,000 miles must have an isolator installed with RTV silicone. Vehicles that exhibit contact and have red rust OR have more than 45,000 miles must have a new brake tube and isolator installed. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > Recalls: > 841 > Feb > 00 > Recall - Fuel Tank Straps and Rear Brake Tube > Page 2686 Parts Information Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Fuel Tank Strap Packages to service about 25% of those vehicles. In addition, each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive ONE (1) Rear Brake Tube, PN 52102243AC. Additional brake tubes should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require rear brake tube replacement. SERVICE PROCEDURE A. Inspect Rear Brake Tube: 1. Raise the vehicle on an appropriate hoist. 2. For vehicles equipped with a fuel tank skid plate: a. Place a transmission jack under the fuel tank skid plate and support the skid plate. b. Remove the inboard screws that attach the skid plate to the frame crossmember (Figure 1) c. Remove the bolts that attach the skid plate to the frame rail (Figure 1). d. Lower the skid plate and remove it from under the vehicle. 3. Remove the three (3) bolts that attach the evaporative canister bracket to the fraim rail and body. set the evaporative canister aside. 4. Using a mirror and flashlight, inspect the top of the rear brake tube where it is routed near the body crossmember just above the front of the fuel tank (Figure 2). 5. If there is evidence of brake tube contact and there is red rust on the brake tube, the brake tube must be replaced. Continue with Section "C" - Replace Fuel Tank Straps and Rear Brake Tube. Tubes with white powder or other residue/discoloration do not require replacement. If there is evidence of contact with NO RED RUST on the brake tube but the vehicle has MORE than 45,000 miles, the brake tube must be replaced. Continue with Section "C" - Replace Fuel Tank Straps and Rear Brake Tube. If there is evidence of contact with no red rust on the brake tube but the vehicle has less than 45,000 miles, the brake tube does NOT require replacement. Continue with Section "B" - Replace Fuel Tank Straps and Install Isolator. If there is no evidence of brake tube contact, the brake tube does not require replacement. continue with section "B" - replace fuel tank straps and install isolator. B. Replace Fuel Tank Straps and Install Isolator: 1. Clean the area of the brake tube shown in Figure 3 with Brake Clean, PN 04897150AA. 2. If the inspection in Section "A" determined that there was brake tube contact with the body crossmember and there was no red rust, coat the brake tube contact area with RTV Sealant (Mopar PN 82300234 or equivalent). 3. Fill the cavity of the provided brake tube rubber isolator with RTV Sealant (Mopar PN 82300234 or equivalent). 4. Snap the isolator over the brake tube. Center the isolator over the area of the tube that is closest to the body crossmember (Figure 3). Position the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > Recalls: > 841 > Feb > 00 > Recall - Fuel Tank Straps and Rear Brake Tube > Page 2687 isolator with the slit toward the ground. NOTE: It is acceptable, and likely, that the rubber isolator will be in contact with the body crossmember. Do NOT bend the brake tube to avoid contact with the body crossmember. 5. Place a transmission jack under the fuel tank and support the fuel tank. 6. Remove the front tank strap mounting nut and remove the front tank strap (Figure 4). NOTE: Lower the fuel tank slightly to ease removal of the strap. 7. Install the provided front tank strap (Figure 4). Tighten the strap mounting nut to 30 ft-lbs (41 Nm). 8. Remove the rear tank strap mounting nut and remove the rear tank strap (Figure 2). NOTE: Lower the fuel tank slightly to ease removal of the strap. 9. Install the provided rear tank strap (Figure 2). Tighten the strap mounting nut to 30 ft-lbs (41 Nm). 10. Remove the transmission jack. 11. Install the evaporative canister and bracket assembly. Tighten the three (3) bolts that attach the evaporative canister bracket to the frame rail and body to 90 in-lbs (10 Nm). 12. For vehicles equipped with a fuel tank skid plate: a. Position the skid plate under the vehicle and support it with a transmission jack. b. Install the inboard screws that attach the skid plate to the frame crossmember (Figure 1). Tighten the screws to 30 ft-lbs (41 Nm) c. Install the bolts that attach the skid plate to the frame rail (Figure 1). Tighten the bolts to 17 ft-lbs (23 Nm). d. Remove the transmission jack. 13. Lower the vehicle. C. Replace Fuel Tank Straps and Rear Brake Tube: NOTE: Only those vehicles that have damaged brake tubes, as determined by the inspection in Section "A", require replacement. Very few vehicles are expected to require brake tube replacement. 1. Lower vehicle. Depress and hold the brake pedal using a brake pedal prop rod. NOTE: Keeping the brake pedal in the "applied" position makes bleeding the brakes faster and easier since only the rear brakes will require bleeding. 3. Raise vehicle on hoist. 4. Disconnect the fuel tank fuel filler vent hose from the vent tube. Do not disconnect vent hose from fuel tank. 5. Insert a siphon hose through the~ vent hose and drain the fuel into an approved gasoline container. 6. Place a transmission jack under the fuel tank and support the fuel tank. 7. Remove the front tank strap mounting nut, then remove and discard the front tank strap (Figure 5). NOTE: Lower the fuel tank slightly to ease removal of the straps. 8. Remove the rear tank strap mounting nut, then remove and discard the rear tank strap (Figure 5). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > Recalls: > 841 > Feb > 00 > Recall - Fuel Tank Straps and Rear Brake Tube > Page 2688 9. Lower the fuel tank approximately six inches (6") and move it inboard to allow access to the rear brake tube. 10. Disconnect the rear brake tube from the junction block at the front of the vehicle. 11. Remove the rear brake tube from the clips along the frame rail. 12. Disconnect the rear brake tube from the rear brake hose. 13. Remove and discard the rear brake tube by sliding it forward. 14. Install the new brake tube along the frame rail. Make sure that the tube is routed behind the evaporative canister lines and above the fuel tube. 15. Connect the brake tube to the brake hose. Tighten the fitting to 170 in-lbs (19 Nm) 16. Connect the brake tube to the junction block at the front of the vehicle. Tighten the fitting to 145 in-lbs (16 Nm) 17. Clean the area of the brake tube shown in Figure 6 with Brake Clean, PN 04897150AA. 18. Install the brake tube into the clips along the frame rail. 19. Fill the cavity of the provided brake tube isolator with RTV Sealant (Mopar PN 82300234 or equivalent). 20. Snap the isolator over the brake tube. Center the isolator over the area of the tube that is closest to the body crossmember (Figure 6). Position the isolator with the slit toward the ground. NOTE: It is acceptable, and likely, that the rubber isolator will be in contact with the body crossmember. Do NOT bend the brake tube to avoid contact with the body crossmember. 21. Raise the fuel tank into position. 22. Install the provided front tank strap (Figure 5). Tighten the strap mounting nut to 30 ft-lbs (41 Nm). 23. Install the provided rear tank strap (Figure 5). Tighten the strap mounting nut to 30 ft-lbs (41 Nm) 24. Connect the fuel vent hose to the vent tube. Tighten the hose clamp to 25 in-lbs (3 Nm) 25. Bleed both rear brake circuits as follows: a. Fill the master cylinder reservoir with clean brake fluid that conforms to DOT-3 specifications. b. Attach a clear plastic hose to both rear bleeder screws and feed the hoses into a clear jar containing enough fresh brake fluid to submerge the end of the hose. c. Have a helper pump the brake pedal three or four times and then hold it in the down position. d. With the pedal in the down position, open the right bleeder screw at least one full turn. e. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. f. Alternating between the right and left side, repeat steps "C" through "E" until all trapped air is removed from the rear brake circuits (usually four or five times). 26. Top off the master cylinder, then inspect the brake tube connections to ensure that there are no leaks. 27. Install the evaporative canister and bracket assembly. Tighten the three (3) bolts that attach the evaporative canister bracket to the frame rail and body to 90 in-lbs (10 Nm). 28. For vehicles equipped with a fuel tank skid plate: a. Position the skid plate under the vehicle and support it with a transmission jack. b. Install the inboard screws that attach the skid plate to the frame crossmember (Figure 1). Tighten the screws to 30 ft-lbs (41 Nm) c. Install the bolts that attach the skid plate to the frame rail (Figure 1). Tighten the bolts to 17 ft-lbs (23 Nm) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > Recalls: > 841 > Feb > 00 > Recall - Fuel Tank Straps and Rear Brake Tube > Page 2689 d. Remove the transmission jack. 29. Lower the vehicle. 30. Refill the fuel tank and ensure that there are no leaks. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time Allowances Add the cost of the recall parts package and brake tube, if necessary, plus applicable dealer allowance to your claim. NOTE: See the warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return: Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MD52 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION1' prompt, then type 110RD84111. 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 copy of the owner notification letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > Recalls: > 841 > Feb > 00 > Recall - Fuel Tank Straps and Rear Brake Tube > Page 2690 DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > Recalls: > NHTSA99V342000 > Dec > 99 > Recall 99V342000: Fuel Tank Strap Defect Fuel Tank Mounting Straps: Recalls Recall 99V342000: Fuel Tank Strap Defect The fuel tank strap can separate due to fatigue during operation. If this occurs, the tank will be unsupported, increasing the risk of a fuel leak. Fuel leakage, in the presence of an ignition source, could result in a fire. Dealers will replace the double toggle lock fuel tank straps with single toggle lock design. NOTE: Affected vehicles built through May 21, 1998, also require the rear brake tube inspection/repair. As a result, the fuel tank strap and brake tube repair will be performed on these vehicles in a single service procedure under recall 99V-341/DaimlerChrysler #841. Affected vehicles built from May 22, 1998 through September 25, 1999, only require the fuel tank strap repair, which will be performed under recall 99V-342/DaimlerChrysler #842. Owner notification began February 7, 2000. 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 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 842 > Feb > 00 > Recall Fuel Tank Straps Fuel Tank Mounting Straps: All Technical Service Bulletins Recall - Fuel Tank Straps NO 842 DATE 02/04/00 Safety Recall # 842 - Fuel Tank Straps February 2000 Dealer Service Instructions for: Models 1998-1999 (DN) Dodge Durango Dealers Service Instructions for: Safety Recall # 842 - Fuel Tank Straps NOTE: This recall applies only to the above vehicles built from May 22, 1998 through September 25, 1998 (MDH 0522XX through 0925XX) NOTE: Safety Recall No. 841 also involves fuel tank strap replacement but applies to earlier built vehicles that also require a brake tube inspection. RECALL MATERIAL ENCLOSED IMMEDIATE ACTION REQUIRED The envelope contains one copy of the dealer recall service instruction letter. In addition, a VIN listing is included for those dealers to whom involved vehicles were invoiced. THE OWNER NOTIFICATION MAILING FOR THIS RECALL WILL BEGIN IN ABOUT ONE WEEK. Please advise the appropriate dealer personnel to forward the orange bordered recall envelope to your service manager as soon as it is received. Doing so will insure that 'our dealership is ready to schedule and repair involved vehicles 3 soon as possible. Additional copies of the recall notification letter will be forwarded via DCMMS mail and the MDS2 in the near future. The entire dealer recall notification letter (excluding graphics) is provided below for your information. 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 DIAL VIP System. SUBJECT The fuel tank straps on about 55,000 of the above vehicles may fatigue and separate. If this occurs, the fuel tank will loosen and could leak fuel. Fuel leakage in the presence of an ignition source can result in an underbody fire. REPAIR The front and rear fuel tank straps must be replaced. Parts Information Part Number Description CBNF841O Fuel Tank Strap Package Each package contains the following components: Quantity Description 1 Fuel Tank Strap - Front 1 Fuel Tank Strap - Rear 1 Rubber Isolator NOTE: The rubber isolator that is included in the package is not used for this recall service procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 842 > Feb > 00 > Recall Fuel Tank Straps > Page 2700 Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Fuel Tank Strap Packages to service about 25% of those vehicles. SERVICE PROCEDURE 1. Raise the vehicle on an appropriate hoist. 2. For vehicles equipped with a fuel tank skid plate: a. Place a transmission jack under the fuel tank skid plate and support the skid plate. b. Remove the inboard screws that attach the skid plate to the frame crossmember. C. Remove the bolts that attach the skid plate to the frame rail . d. Lower the skid plate and remove it from under the vehicle. 3. Place a transmission jack under the fuel tank and support the fuel tank. 4. Remove the front tank strap mounting nut and remove the front tank strap. NOTE: Lower the fuel tank slightly to ease removal of the strap from the mounting hole. 5. Install the provided front tank strap. Tighten the strap mounting nut to 30 ft-lbs (41 Nm). 6. Remove the rear tank strap mounting nut and remove the rear tank strap. NOTE: Lower the fuel tank slightly to ease removal of the strap from the mounting hole. 7. Install the provided rear tank strap. Tighten the strap mounting nut to 30 ft-lbs (41 Nm). Remove the transmission jack. 9. For vehicles equipped with a fuel tank skid plate: a. Position the skid plate under the vehicle and support it with a transmission jack. b. Install the inboard screws that attach the skid plate to the frame crossmember. Tighten the screws to 30 ft-lbs (41 Nm) C. Install the bolts that attach the skid plate to the frame rail (Figure 1). Tighten the bolts to 17 ft-lbs (23 Nm) d. Remove the transmission jack. 10. Lower the vehicle. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time Allowances Add the cost of the recall parts package plus applicable dealer allowance to your claim. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 842 > Feb > 00 > Recall Fuel Tank Straps > Page 2701 NOTE: See the warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return: Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MD52 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Dial System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD842". 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 copy of the owner notification letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service1 let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 841 > Feb > 00 > Recall Fuel Tank Straps and Rear Brake Tube Fuel Tank Mounting Straps: All Technical Service Bulletins Recall - Fuel Tank Straps and Rear Brake Tube NO 841 DATE 02/17/00 SAFETY RECALL 841 Fuel Tank Straps and Rear Brake Tube MODELS 1998 ,(DN) Dodge Durango ATTENTION: Service Manager RECALL MATERIAL ENCLOSED IMMEDIATE ACTION REQUIRED The envelope contains one copy of the dealer recall service instruction letter. In addition, a VIN listing is included for those dealers to whom involved vehicles were invoiced. The owner notification mailing for this recall will begin in about one week. Please advise the appropriate dealer personnel to forward the orange bordered recall envelope to your service manager as soon as it is received. Doing so will insure that our dealership is ready to schedule and repair involved vehicles soon as possible. Additional copies of the recall notification letter will be forwarded via DCMMS mail and the MDS2 in the near future. The entire dealer recall notification letter (excluding graphics) is provided below for your information. February 2000 Dealer Service Instructions for: SAFETY RECALL No. 841 FUEL TANK STRAPS AND REAR BRAKE TUBE. NOTE: This recall applies only to the above vehicles built through May 21, 1998 (MDH 0521XX). NOTE: Safety Recall No. 842 also involves fuel tank strap replacement but applies to later built vehicles that do not require the brake tube inspection. ATTENTION: Service Manager Recall material enclosed immediate action required require the brake tube inspection. 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 DIAL VIP System. SUBJECT The fuel tank straps on about 96,OOO of the above vehicles may fatigue and separate. If this occurs, the fuel tank will loosen and could leak fuel. Fuel leakage in the presence of an ignition source can result in an underbody fire. In addition, the rear brake tube may contact an underbody crossmember. Prolonged brake tube contact may cause the tube to rub through and leak, resulting in a partial brake system loss and increased stopping distance. The increased stopping distance can cause an accident without warning. REPAIR The front and rear fuel tank straps must be replaced, and the rear brake tube must be inspected on all involved vehicles. ~7ehicles without brake tube contact must have a brake tube isolator installed. Vehicles that exhibit contact but have no signs of red rust AND have less than 45,000 miles must have an isolator installed with RTV silicone. Vehicles that exhibit contact and have red rust OR have more than 45,000 miles must have a new brake tube and isolator installed. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 841 > Feb > 00 > Recall Fuel Tank Straps and Rear Brake Tube > Page 2706 Parts Information Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Fuel Tank Strap Packages to service about 25% of those vehicles. In addition, each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive ONE (1) Rear Brake Tube, PN 52102243AC. Additional brake tubes should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require rear brake tube replacement. SERVICE PROCEDURE A. Inspect Rear Brake Tube: 1. Raise the vehicle on an appropriate hoist. 2. For vehicles equipped with a fuel tank skid plate: a. Place a transmission jack under the fuel tank skid plate and support the skid plate. b. Remove the inboard screws that attach the skid plate to the frame crossmember (Figure 1) c. Remove the bolts that attach the skid plate to the frame rail (Figure 1). d. Lower the skid plate and remove it from under the vehicle. 3. Remove the three (3) bolts that attach the evaporative canister bracket to the fraim rail and body. set the evaporative canister aside. 4. Using a mirror and flashlight, inspect the top of the rear brake tube where it is routed near the body crossmember just above the front of the fuel tank (Figure 2). 5. If there is evidence of brake tube contact and there is red rust on the brake tube, the brake tube must be replaced. Continue with Section "C" - Replace Fuel Tank Straps and Rear Brake Tube. Tubes with white powder or other residue/discoloration do not require replacement. If there is evidence of contact with NO RED RUST on the brake tube but the vehicle has MORE than 45,000 miles, the brake tube must be replaced. Continue with Section "C" - Replace Fuel Tank Straps and Rear Brake Tube. If there is evidence of contact with no red rust on the brake tube but the vehicle has less than 45,000 miles, the brake tube does NOT require replacement. Continue with Section "B" - Replace Fuel Tank Straps and Install Isolator. If there is no evidence of brake tube contact, the brake tube does not require replacement. continue with section "B" - replace fuel tank straps and install isolator. B. Replace Fuel Tank Straps and Install Isolator: 1. Clean the area of the brake tube shown in Figure 3 with Brake Clean, PN 04897150AA. 2. If the inspection in Section "A" determined that there was brake tube contact with the body crossmember and there was no red rust, coat the brake tube contact area with RTV Sealant (Mopar PN 82300234 or equivalent). 3. Fill the cavity of the provided brake tube rubber isolator with RTV Sealant (Mopar PN 82300234 or equivalent). 4. Snap the isolator over the brake tube. Center the isolator over the area of the tube that is closest to the body crossmember (Figure 3). Position the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 841 > Feb > 00 > Recall Fuel Tank Straps and Rear Brake Tube > Page 2707 isolator with the slit toward the ground. NOTE: It is acceptable, and likely, that the rubber isolator will be in contact with the body crossmember. Do NOT bend the brake tube to avoid contact with the body crossmember. 5. Place a transmission jack under the fuel tank and support the fuel tank. 6. Remove the front tank strap mounting nut and remove the front tank strap (Figure 4). NOTE: Lower the fuel tank slightly to ease removal of the strap. 7. Install the provided front tank strap (Figure 4). Tighten the strap mounting nut to 30 ft-lbs (41 Nm). 8. Remove the rear tank strap mounting nut and remove the rear tank strap (Figure 2). NOTE: Lower the fuel tank slightly to ease removal of the strap. 9. Install the provided rear tank strap (Figure 2). Tighten the strap mounting nut to 30 ft-lbs (41 Nm). 10. Remove the transmission jack. 11. Install the evaporative canister and bracket assembly. Tighten the three (3) bolts that attach the evaporative canister bracket to the frame rail and body to 90 in-lbs (10 Nm). 12. For vehicles equipped with a fuel tank skid plate: a. Position the skid plate under the vehicle and support it with a transmission jack. b. Install the inboard screws that attach the skid plate to the frame crossmember (Figure 1). Tighten the screws to 30 ft-lbs (41 Nm) c. Install the bolts that attach the skid plate to the frame rail (Figure 1). Tighten the bolts to 17 ft-lbs (23 Nm). d. Remove the transmission jack. 13. Lower the vehicle. C. Replace Fuel Tank Straps and Rear Brake Tube: NOTE: Only those vehicles that have damaged brake tubes, as determined by the inspection in Section "A", require replacement. Very few vehicles are expected to require brake tube replacement. 1. Lower vehicle. Depress and hold the brake pedal using a brake pedal prop rod. NOTE: Keeping the brake pedal in the "applied" position makes bleeding the brakes faster and easier since only the rear brakes will require bleeding. 3. Raise vehicle on hoist. 4. Disconnect the fuel tank fuel filler vent hose from the vent tube. Do not disconnect vent hose from fuel tank. 5. Insert a siphon hose through the~ vent hose and drain the fuel into an approved gasoline container. 6. Place a transmission jack under the fuel tank and support the fuel tank. 7. Remove the front tank strap mounting nut, then remove and discard the front tank strap (Figure 5). NOTE: Lower the fuel tank slightly to ease removal of the straps. 8. Remove the rear tank strap mounting nut, then remove and discard the rear tank strap (Figure 5). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 841 > Feb > 00 > Recall Fuel Tank Straps and Rear Brake Tube > Page 2708 9. Lower the fuel tank approximately six inches (6") and move it inboard to allow access to the rear brake tube. 10. Disconnect the rear brake tube from the junction block at the front of the vehicle. 11. Remove the rear brake tube from the clips along the frame rail. 12. Disconnect the rear brake tube from the rear brake hose. 13. Remove and discard the rear brake tube by sliding it forward. 14. Install the new brake tube along the frame rail. Make sure that the tube is routed behind the evaporative canister lines and above the fuel tube. 15. Connect the brake tube to the brake hose. Tighten the fitting to 170 in-lbs (19 Nm) 16. Connect the brake tube to the junction block at the front of the vehicle. Tighten the fitting to 145 in-lbs (16 Nm) 17. Clean the area of the brake tube shown in Figure 6 with Brake Clean, PN 04897150AA. 18. Install the brake tube into the clips along the frame rail. 19. Fill the cavity of the provided brake tube isolator with RTV Sealant (Mopar PN 82300234 or equivalent). 20. Snap the isolator over the brake tube. Center the isolator over the area of the tube that is closest to the body crossmember (Figure 6). Position the isolator with the slit toward the ground. NOTE: It is acceptable, and likely, that the rubber isolator will be in contact with the body crossmember. Do NOT bend the brake tube to avoid contact with the body crossmember. 21. Raise the fuel tank into position. 22. Install the provided front tank strap (Figure 5). Tighten the strap mounting nut to 30 ft-lbs (41 Nm). 23. Install the provided rear tank strap (Figure 5). Tighten the strap mounting nut to 30 ft-lbs (41 Nm) 24. Connect the fuel vent hose to the vent tube. Tighten the hose clamp to 25 in-lbs (3 Nm) 25. Bleed both rear brake circuits as follows: a. Fill the master cylinder reservoir with clean brake fluid that conforms to DOT-3 specifications. b. Attach a clear plastic hose to both rear bleeder screws and feed the hoses into a clear jar containing enough fresh brake fluid to submerge the end of the hose. c. Have a helper pump the brake pedal three or four times and then hold it in the down position. d. With the pedal in the down position, open the right bleeder screw at least one full turn. e. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. f. Alternating between the right and left side, repeat steps "C" through "E" until all trapped air is removed from the rear brake circuits (usually four or five times). 26. Top off the master cylinder, then inspect the brake tube connections to ensure that there are no leaks. 27. Install the evaporative canister and bracket assembly. Tighten the three (3) bolts that attach the evaporative canister bracket to the frame rail and body to 90 in-lbs (10 Nm). 28. For vehicles equipped with a fuel tank skid plate: a. Position the skid plate under the vehicle and support it with a transmission jack. b. Install the inboard screws that attach the skid plate to the frame crossmember (Figure 1). Tighten the screws to 30 ft-lbs (41 Nm) c. Install the bolts that attach the skid plate to the frame rail (Figure 1). Tighten the bolts to 17 ft-lbs (23 Nm) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 841 > Feb > 00 > Recall Fuel Tank Straps and Rear Brake Tube > Page 2709 d. Remove the transmission jack. 29. Lower the vehicle. 30. Refill the fuel tank and ensure that there are no leaks. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time Allowances Add the cost of the recall parts package and brake tube, if necessary, plus applicable dealer allowance to your claim. NOTE: See the warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return: Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MD52 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION1' prompt, then type 110RD84111. 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 copy of the owner notification letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 841 > Feb > 00 > Recall Fuel Tank Straps and Rear Brake Tube > Page 2710 DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > NHTSA99V342000 > Dec > 99 > Recall 99V342000: Fuel Tank Strap Defect Fuel Tank Mounting Straps: All Technical Service Bulletins Recall 99V342000: Fuel Tank Strap Defect The fuel tank strap can separate due to fatigue during operation. If this occurs, the tank will be unsupported, increasing the risk of a fuel leak. Fuel leakage, in the presence of an ignition source, could result in a fire. Dealers will replace the double toggle lock fuel tank straps with single toggle lock design. NOTE: Affected vehicles built through May 21, 1998, also require the rear brake tube inspection/repair. As a result, the fuel tank strap and brake tube repair will be performed on these vehicles in a single service procedure under recall 99V-341/DaimlerChrysler #841. Affected vehicles built from May 22, 1998 through September 25, 1999, only require the fuel tank strap repair, which will be performed under recall 99V-342/DaimlerChrysler #842. Owner notification began February 7, 2000. 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 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Tank Mounting Straps: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption Intake Manifold: All Technical Service Bulletins Engine - Spark Knock/Oil Consumption NUMBER: 09-05-00 GROUP: Engine DATE: Feb.25, 2000 MODELS: 1994 - 1999 (AB) Ram Van 1994 - 1999 (AN) Dakota 1994 - 1999 (BRIBE) Ram Truck 1998 - 1999 (DN) Durango 1994 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-06-99, DATED SEP.10, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Spark Knock And Engine Oil Consumption Due To Intake Manifold Pan Gasket Oil Leak OVER VIEW: This bulletin involves the replacement of the engine intake manifold plenum pan gasket. NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH A 3.9L, 5.2L. OR 5.9L GASOLINE ENGINE. SYMPTOM/CONDITION: An engine intake manifold plenum pan gasket oil leak may occur on some V-6 and V-8 style engines. The oil leak is internal to the engine so no external oil leakage will be present. Two symptoms of this oil leak condition may be present. The vehicle operator may experience an engine spark knock during acceleration and/or an increase in the amount of engine oil consumed by the engine. DIAGNOSIS: Make sure Technical Service Bulletin (TSB) 18-48-98 has been performed. NOTE: IT IS IMPORTANT THAT THE COIL AND SPARK PLUG WIRES ARE ROUTED EXACTLY AS SPECIFIED IN TSB 18-48-98 TO ACHIEVE THE MOST BENEFIT. Inspect the Positive Crankcase Ventilation (PCV) valve. Shake the PCV valve to verify that the pintle inside of the PCV valve is free. Replace the PVC if the pintle is not free. If the intake manifold plenum pan gasket is leaking, an additional vacuum source will be created inside of the engine at the location of the pan gasket leakage. Engine combustion blow-by gases, oil vapor, and air from the crankcase filter/breather may be drawn past the leaking pan gasket and into the intake manifold. In most cases when this condition occurs, an engine at idle will create the highest vacuum and lowest amount of engine blow-by. 1. Allow the engine to reach normal operating temperature. 2. Stop the engine. 3. Disconnect the breather hose from the air cleaner. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Tank Mounting Straps: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 2720 4. Attach a vacuum/pressure gauge to the end of the breather hose (Figure 1). 5. Disconnect the PCV valve hose from the intake manifold. 6. Seal off the intake manifold PCV valve hose port opening. 7. Seal off the open end of the PCV valve hose (Figure 2). NOTE: DURING THIS DIAGNOSIS, IT WOULD BE NORMAL FOR THE ENGINE TO DEVELOP PRESSURE WITHIN THE ENGINE CRANKCASE. THIS IS DUE TO THE NORMAL PROCESS OF EXHAUST BLOW-BY GASES LEAKING PAST THE ENGINE PISTON RINGS AND ACCUMULATING IN THE ENGINE CRANKCASE. DO NOT ALLOW MORE THAN 3 PSI (20.7 kpa) OF PRESSURE TO BUILD WITHIN THE ENGINE WHEN PERFORMING THE FOLLOWING DIAGNOSTIC PROCEDURE. 8. Start the warmed engine and observe the vacuum gauge. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Tank Mounting Straps: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 2721 9. Allow the engine to idle for approximately 30 seconds. Do not allow more than 3 psi (20.7 kPa) of pressure to develop in the engine crankcase. 10. If the attached vacuum / pressure gauge does not indicate that a vacuum is present in the engine crankcase, then the intake manifold plenum pan gasket is good and no further internal engine vacuum leak diagnosis is required. 11. If an internal vacuum leak is present then perform the Repair Procedure. PARTS REQUIRED: For the 5.2L / 5.9L: 1 04897383AC Package, Intake Manifold Flange Gasket and Bolts 1 05017208AA Gasket, Intake Manifold Plenum Pan 15 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR) 04318001 Conditioner, Combustion Chamber For the 3.9L: 1 04897382AC Package, Intake Manifold Flange Gasket and Bolts 1 05017207AA Gasket, Intake Manifold Plenum Pan 14 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR)04318001 Conditioner, Combustion Chamber REPAIR PROCEDURE: 1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation instructions. NOTE: CLEAN ALL OIL RESIDUE FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND THE INTAKE MANIFOLD PLENUM CHAMBER. NOTE: THE PROPER BOLT TORQUE AND TIGHTENING SEQUENCE IS CRITICAL AND MUST BE FOLLOWED WHEN TIGHTENING BOTH THE PLENUM PAN BOLTS AND THE INTAKE MANIFOLD FLANGE BOLTS. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Tank Mounting Straps: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 2722 3.9L Bolt Tightening Sequence and Torque Procedure: 3.9 Plenum Pan Bolt Torque Procedure 3.9 Intake Manifold Flange Bolt Torque Procedure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Tank Mounting Straps: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 2723 5.2L / 5.9L Plenum Bolt Tightening Sequence and Torque Procedure: 5.2L / 5.9L Plenum Pan Bolt Torque Procedure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Tank Mounting Straps: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 2724 5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure 2. With the engine reassembled, inspect the coil and spark plug wires for proper routing. Refer to TSB 09-48-98 for additional assistance. 3. Start the engine and allow it to warm to normal engine operating temperature. 4. Decarbon the combustion chamber using Mopar Combustion Chamber Conditioner (p/n 04318001) per the instructions. NOTE: ALLOW THE COMBUSTION CHAMBER CLEANER TO SOAK INSIDE OF THE ENGINE FOR 2 TO 2.5 HOURS. NOTE: A SECOND APPLICATION OF THE COMBUSTION CHAMBER CONDITIONER MAY BE REQUIRED IF THERE WAS A LARGE QUANTITY OF OIL LEAKAGE PAST THE INTAKE PLENUM PAN GASKET. 5. Verify proper engine oil level. POLICY: Reimbursable within the provisions of the warranty. Time Allowance FAILURE CODE: P8- New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Tank Mounting Straps: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 2730 4. Attach a vacuum/pressure gauge to the end of the breather hose (Figure 1). 5. Disconnect the PCV valve hose from the intake manifold. 6. Seal off the intake manifold PCV valve hose port opening. 7. Seal off the open end of the PCV valve hose (Figure 2). NOTE: DURING THIS DIAGNOSIS, IT WOULD BE NORMAL FOR THE ENGINE TO DEVELOP PRESSURE WITHIN THE ENGINE CRANKCASE. THIS IS DUE TO THE NORMAL PROCESS OF EXHAUST BLOW-BY GASES LEAKING PAST THE ENGINE PISTON RINGS AND ACCUMULATING IN THE ENGINE CRANKCASE. DO NOT ALLOW MORE THAN 3 PSI (20.7 kpa) OF PRESSURE TO BUILD WITHIN THE ENGINE WHEN PERFORMING THE FOLLOWING DIAGNOSTIC PROCEDURE. 8. Start the warmed engine and observe the vacuum gauge. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Tank Mounting Straps: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 2731 9. Allow the engine to idle for approximately 30 seconds. Do not allow more than 3 psi (20.7 kPa) of pressure to develop in the engine crankcase. 10. If the attached vacuum / pressure gauge does not indicate that a vacuum is present in the engine crankcase, then the intake manifold plenum pan gasket is good and no further internal engine vacuum leak diagnosis is required. 11. If an internal vacuum leak is present then perform the Repair Procedure. PARTS REQUIRED: For the 5.2L / 5.9L: 1 04897383AC Package, Intake Manifold Flange Gasket and Bolts 1 05017208AA Gasket, Intake Manifold Plenum Pan 15 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR) 04318001 Conditioner, Combustion Chamber For the 3.9L: 1 04897382AC Package, Intake Manifold Flange Gasket and Bolts 1 05017207AA Gasket, Intake Manifold Plenum Pan 14 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR)04318001 Conditioner, Combustion Chamber REPAIR PROCEDURE: 1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation instructions. NOTE: CLEAN ALL OIL RESIDUE FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND THE INTAKE MANIFOLD PLENUM CHAMBER. NOTE: THE PROPER BOLT TORQUE AND TIGHTENING SEQUENCE IS CRITICAL AND MUST BE FOLLOWED WHEN TIGHTENING BOTH THE PLENUM PAN BOLTS AND THE INTAKE MANIFOLD FLANGE BOLTS. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Tank Mounting Straps: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 2732 3.9L Bolt Tightening Sequence and Torque Procedure: 3.9 Plenum Pan Bolt Torque Procedure 3.9 Intake Manifold Flange Bolt Torque Procedure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Tank Mounting Straps: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 2733 5.2L / 5.9L Plenum Bolt Tightening Sequence and Torque Procedure: 5.2L / 5.9L Plenum Pan Bolt Torque Procedure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Tank Mounting Straps: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 2734 5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure 2. With the engine reassembled, inspect the coil and spark plug wires for proper routing. Refer to TSB 09-48-98 for additional assistance. 3. Start the engine and allow it to warm to normal engine operating temperature. 4. Decarbon the combustion chamber using Mopar Combustion Chamber Conditioner (p/n 04318001) per the instructions. NOTE: ALLOW THE COMBUSTION CHAMBER CLEANER TO SOAK INSIDE OF THE ENGINE FOR 2 TO 2.5 HOURS. NOTE: A SECOND APPLICATION OF THE COMBUSTION CHAMBER CONDITIONER MAY BE REQUIRED IF THERE WAS A LARGE QUANTITY OF OIL LEAKAGE PAST THE INTAKE PLENUM PAN GASKET. 5. Verify proper engine oil level. POLICY: Reimbursable within the provisions of the warranty. Time Allowance FAILURE CODE: P8- New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications IAC Motor-To-Throttle Body Bolts 7 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2738 Idle Speed/Throttle Actuator - Electronic: Locations Mounting Bolts(Screws)-IAC Motor MAP Sensor, Idle Air Control Motor, Throttle Position Sensor The IAC motor is mounted to the back of the throttle body Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2739 Idle Air Control Motor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2740 Idle Speed/Throttle Actuator - Electronic: Description and Operation Throttle Body Air Control Passage IDLE AIR CONTROL (IAC) MOTOR-PCM OUTPUT The IAC motor is mounted to the back of the throttle body and is controlled by the Powertrain Control Module (PCM). The throttle body has an air control passage that provides air for the engine at idle (the throttle plate is closed). The IAC motor pintle protrudes into the air control passage and regulates air flow through it. Based on various sensor inputs, the Powertrain Control Module (PCM) adjusts engine idle speed by moving the IAC motor pintle in and out of the air control passage. The IAC motor is positioned when the ignition key is turned to the On position. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2741 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection To perform a complete test of the IAC motor and its circuitry, refer to Computers and Control Systems/Testing and Inspection. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2742 Idle Speed/Throttle Actuator - Electronic: Service and Repair Mounting Bolts(Screws)-IAC Motor The IAC motor is located on the back of the throttle body. REMOVAL 1. Remove air duct at throttle body. 2. Disconnect electrical connector from 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 at throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Power Distributor Center (PDC) Location Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2746 Power Distribution Center The ASD relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2747 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down (ASD) Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2748 Automatic Shut Down (ASD) Relay: Description and Operation AUTOMATIC SHUTDOWN (ASD) RELAY SENSE-PCM INPUT Power Distribution Center(PDC) A 12 volt signal at this input indicates to the Powertrain Control Module (PCM) that the ASD has been activated. The ASD relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. 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 PCM does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). AUTO SHUTDOWN (ASD) RELAY-PCM OUTPUT The ASD relay is located in the Power Distribution Center (PDC). The ASD supplies battery voltage to the fuel injectors, ignition coil and oxygen (O2S) sensor heating elements. The ground circuit for the coil in the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the relay by switching the ground circuit on and off. AUTOMATIC SHUTDOWN (ASD) RELAY As one of its functions, the ASD relay will supply battery voltage to the ignition coil. The ground circuit for the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM regulates ASD relay operation by switching the ground circuit on-and-off. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2749 Automatic Shut Down (ASD) Relay: Testing and Inspection ASD And Fuel Pump Relay Terminals 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. Operation 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. Testing The following procedure applies to the ASD and fuel pump relays. 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 ± 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 source5 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2750 Automatic Shut Down (ASD) Relay: Service and Repair Power Distributor Center (PDC) Location The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. REMOVAL 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 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Distributor Center (PDC) Location Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2755 Power Distribution Center The fuel pump relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2756 Fuel Pump Relay: Diagrams Power Distribution Center Fuel Pump Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2757 Fuel Pump Relay: Description and Operation FUEL PUMP RELAY-PCM OUTPUT The PCM energizes the electric fuel pump through the fuel pump relay. Battery voltage is applied to the fuel pump relay when the ignition key is ON. The relay is energized when a ground signal is provided by the PCM. The fuel pump will operate for approximately one second unless the engine is operating or the starter motor is engaged. The fuel pump relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2758 Fuel Pump Relay: Testing and Inspection ASD And Fuel Pump Relay Terminals 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. Operation 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. Testing The following procedure applies to the ASD and fuel pump relays. 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 ± 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 source5 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2759 Fuel Pump Relay: Service and Repair Power Distributor Center (PDC) Location The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. REMOVAL 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 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Power Distributor Center (PDC) Location Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2763 Power Distribution Center The ASD relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2764 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down (ASD) Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2765 Automatic Shut Down (ASD) Relay: Description and Operation AUTOMATIC SHUTDOWN (ASD) RELAY SENSE-PCM INPUT Power Distribution Center(PDC) A 12 volt signal at this input indicates to the Powertrain Control Module (PCM) that the ASD has been activated. The ASD relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. 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 PCM does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). AUTO SHUTDOWN (ASD) RELAY-PCM OUTPUT The ASD relay is located in the Power Distribution Center (PDC). The ASD supplies battery voltage to the fuel injectors, ignition coil and oxygen (O2S) sensor heating elements. The ground circuit for the coil in the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the relay by switching the ground circuit on and off. AUTOMATIC SHUTDOWN (ASD) RELAY As one of its functions, the ASD relay will supply battery voltage to the ignition coil. The ground circuit for the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM regulates ASD relay operation by switching the ground circuit on-and-off. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2766 Automatic Shut Down (ASD) Relay: Testing and Inspection ASD And Fuel Pump Relay Terminals 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. Operation 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. Testing The following procedure applies to the ASD and fuel pump relays. 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 ± 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 source5 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2767 Automatic Shut Down (ASD) Relay: Service and Repair Power Distributor Center (PDC) Location The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. REMOVAL 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 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Locations Rollover Valve: Locations Rollover Valve Locations The front Rollover 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Locations > Page 2771 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 IN FUEL SYSTEM . Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Locations > Page 2772 Rollover Valve: Description and Operation 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. The 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 in Fuel System. The front valve can be serviced separately. Refer to Rollover Valves. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Locations > Page 2773 Rollover Valve: Service and Repair Rollover Valve Locations Two rollover valves are used. One of the valves is permanently mounted to top/rear of fuel tank. If replacement of this particular valve is necessary, the fuel tank must be replaced. Refer to Fuel Tank Removal/Installation in fuel system.The other rollover valve is located on top of the fuel pump module. This valve may be serviced separately. Refer to following steps for procedures. REMOVAL 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 IN FUEL SYSTEM. 1. Disconnect negative battery cable at battery. 2. Remove fuel filler cap and drain fuel tank. 3. Remove fuel tank. Refer to Fuel Tank Removal/Installation in Fuel System. 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 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2778 Throttle Position Sensor: Locations MAP And Throttle Position Sensor Location The throttle position sensor (TPS) is mounted on the throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2779 Throttle Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2780 Throttle Position Sensor: Description and Operation MAP And Throttle Position Sensor Location THROTTLE POSITION SENSOR (TPS)-PCM INPUT The throttle position sensor (TPS) is mounted on the throttle body. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents throttle blade position. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2781 Throttle Position Sensor: Testing and Inspection To perform a complete test of the TPS and its circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the TPS only, refer to the following: Throttle Position Sensor The TPS can be tested with a digital voltmeter. The center electrical terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). At idle, TPS output voltage should be greater than 0.26 volts but less than 0.95 volts. At wide open throttle, TPS output voltage must be less than 4.49 volts. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2782 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on side of throttle body. 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body. INSTALLATION Installation-Typical The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications Throttle Body: Specifications Throttle Body Bolts 200 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 2786 Throttle Body: Description and Operation Throttle Body Air Control Passage THROTTLE BODY-3.9/5.2/5.9L ENGINES Filtered air from the air cleaner enters the intake manifold through the throttle body. Fuel does not enter the intake manifold through the throttle body. Fuel is sprayed into the manifold by the fuel injectors. The throttle body is mounted on the intake manifold. It contains an air control passage controlled by an idle air control (IAC) motor. The air control passage is used to supply air for idle conditions. A throttle valve (plate) is used to supply air for above idle conditions. The throttle position sensor (TPS), idle air control (IAC) motor and manifold absolute pressure sensor (MAP) are attached to the throttle body. The accelerator pedal cable, speed control cable and transmission control cable (when equipped) are connected to the throttle arm. A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the PCM. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 2787 Throttle Body: Testing and Inspection The following test procedure has been developed to check throttle body calibrations for correct idle conditions. The procedure should be used to diagnose the throttle body for conditions that may cause idle problems. This procedure should be used only after normal diagnostic procedures have failed to produce results that indicate a throttle body related problem. Be sure to check for proper operation of the idle air control motor before performing this test. Fixed Orifice Tool A special fixed orifice tool (number 6714) must be used for the following test. 1. Start the engine and bring to operating temperature. Be sure all accessories are off before performing this test. 2. Shut off the engine and remove the air duct at throttle body. Install Orifice Tool 3. Disconnect the vacuum line at the PCV valve. 4. Install the 0.185 inch orifice tool (number 6714) into the disconnected vacuum line in place of the PCV valve. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 2788 Idle Purge Line 5. Disconnect the idle purge vacuum line from fitting at throttle body. This vacuum line is located on the front of throttle body next to the MAP sensor. Cap the fitting at throttle body after vacuum line has been removed. 6. Connect the DRB scan tool to the 16-way data link connector. This connector is located under the instrument panel to the left of the steering column. Refer to the appropriate Powertrain Diagnostic Procedures service for DRB operation. 7. Start the engine and allow to warm up. 8. Using the DRB scan tool, scroll through the menus as follows: select-Stand Alone DRB III, select 1999 Diagnostics, select-Engine, select-System Test, select-Minimum Air Flow. 9. The DRB scan tool will count down to stabilize the idle rpm and display the minimum air flow idle rpm. The idle rpm should be between 500 and 900 rpm. If the idle speed is outside of these specifications, replace the throttle body. Refer to Throttle Body in the Component Removal/Installation. 10. Disconnect the DRB scan tool from the vehicle. 11. Remove cap from idle purge fitting at throttle body and install vacuum line. 12. Remove orifice tool and connect vacuum line to PCV valve. 13. Install air duct to throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 2789 Throttle Body: Service and Repair A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the Powertrain Control Module (PCM). REMOVAL 1. Remove the air duct at throttle body. Sensor Electrical Connectors-Typical 2. Disconnect throttle body electrical connectors at MAP sensor, IAC motor and TPS. 3. Remove vacuum line at throttle body. 4. Remove all control cables from throttle body (lever) arm. Refer to the Accelerator Pedal and Throttle Cable for additional information. Throttle Body Mounting Bolts-Typical 5. Remove four throttle body mounting bolts. 6. Remove throttle body from intake manifold. 7. Discard old throttle body-to-intake manifold gasket. INSTALLATION 1. Clean the mating surfaces of the throttle body and the intake manifold. 2. Install new throttle body-to-intake manifold gasket. 3. Install throttle body to intake manifold. 4. Install four mounting bolts. Tighten bolts to 23 Nm (200 in. lbs.) torque. 5. Install control cables. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 2790 6. Install vacuum line to throttle body. 7. Install electrical connectors. 8. Install air duct at throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair Throttle Cable/Linkage: Service and Repair CAUTION: Be careful not to damage or kink cable core wire (within cable sheathing) while servicing accelerator pedal or cables. REMOVAL Accelerator Pedal - Removal Or Installation 1. From inside vehicle, hold up accelerator pedal. Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm. Plastic cable retainer snaps into pedal arm. 2. Remove cable core wire at pedal arm. 3. From inside vehicle, pinch both sides of cable housing retainer at dash panel. Remove cable housing from dash panel and pull into engine compartment. 4. Remove air tube at top of throttle body. Throttle Cable At Throttle Body - Typical(V-8) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 2794 5. Operate throttle body lever (by hand) to full open throttle position. Slip cable end rearward from pin on throttle lever. Cable Release Tab-typical 6. Remove cable housing at throttle body mounting bracket by pressing forward on release tab with a small screwdriver. To prevent cable housing breakage, press on tab only enough to release cable from bracket. Lift cable housing straight up from bracket while pressing on release tab. Remove cable housing. INSTALLATION 1. Snap cable end onto lever pin. On models with V-8 engines, be sure cable is routed under plastic cam. 2. Connect cable to throttle body mounting bracket (push down and lock). 3. Install remaining cable housing end into dash panel opening (snaps into position). Index Tab And Slot 4. Install ball end of cable wire through hole in pedal arm. Install plastic cable retainer. The plastic retainer is snapped into pedal arm. When installing retainer to accelerator pedal arm, note index tab on pedal arm. Align index slot on plastic retainer to this index tab. 5. Operate and test throttle before starting engine. 6. Install air tube to throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2798 Throttle Position Sensor: Locations MAP And Throttle Position Sensor Location The throttle position sensor (TPS) is mounted on the throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2799 Throttle Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2800 Throttle Position Sensor: Description and Operation MAP And Throttle Position Sensor Location THROTTLE POSITION SENSOR (TPS)-PCM INPUT The throttle position sensor (TPS) is mounted on the throttle body. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents throttle blade position. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2801 Throttle Position Sensor: Testing and Inspection To perform a complete test of the TPS and its circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the TPS only, refer to the following: Throttle Position Sensor The TPS can be tested with a digital voltmeter. The center electrical terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). At idle, TPS output voltage should be greater than 0.26 volts but less than 0.95 volts. At wide open throttle, TPS output voltage must be less than 4.49 volts. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2802 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on side of throttle body. 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body. INSTALLATION Installation-Typical The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor Oil Pressure Sending Unit/Switch, Camshaft Position Sensor Connector The camshaft position sensor is located in the distributor on all engines. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2814 Camshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2815 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor CAMSHAFT POSITION SENSOR - PCM INPUT A sync signal is provide by the camshaft position sensor located in the distributor. The sync signal from this sensor works in conjunction with the crankshaft position sensor to provide the Powertrain Control Module (PCM) with inputs. This is done to establish and maintain correct injector firing order. CAMSHAFT POSITION SENSOR The camshaft position sensor is located in the distributor on all engines. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2816 Camshaft Position Sensor: Testing and Inspection Camshaft Position Sensor The camshaft position sensor is located in the distributor on all engines. To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: For this test, an analog (non-digital) voltmeter is needed. Do not remove the distributor connector from the distributor. Using small paper clips, insert them into the backside of the distributor wire harness connector to make contact with the terminals. Be sure that the connector is not damaged when inserting the paper clips. Attach voltmeter leads to these paper clips. 1. Connect the positive (+) voltmeter lead into the sensor output wire. This is at done the distributor wire harness connector. 2. Connect the negative (-) voltmeter lead into the ground wire. 3. Set the voltmeter to the 15 Volt DC scale. 4. Remove distributor cap from distributor (two screws). Rotate (crank) the engine until the distributor rotor is pointed towards the rear of vehicle. The movable pulse ring should now be within the sensor pickup. 5. Turn ignition key to ON position. Voltmeter should read approximately 5.0 volts. 6. If voltage is not present, check the voltmeter leads for a good connection. 7. If voltage is still not present, check for voltage at the supply wire. For wire identification, refer to Wiring Diagrams. 8. If 5 volts is not present at supply wire, check for voltage at PCM 32-way connector (cavity A-17). Leave the PCM connector connected for this test. 9. If voltage is still not present, perform vehicle test using the DRB scan tool. 10. If voltage is present at cavity A-17, but not at the supply wire: a. Check continuity between the supply wire. This is checked between the distributor connector and cavity A-17 at the PCM. If continuity is not present, repair the harness as necessary. b. Check for continuity between the camshaft position sensor output wire and cavity A-18 at the PCM, If continuity is not present, repair the harness as necessary. c. Check for continuity between the ground circuit wire at the distributor connector and ground. If continuity is not present, repair the harness as necessary. 11. While observing the voltmeter, crank the engine with ignition switch. The voltmeter needle should fluctuate between 0 and 5 volts while the engine is cranking. This verifies that the camshaft position sensor in the distributor is operating properly and a sync pulse signal is being generated. If sync pulse signal is not present, replacement of the camshaft position sensor is necessary Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2817 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor The camshaft position sensor is located in the distributor on all engines. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove air cleaner assembly. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. tighten mounting screws. 5. Install air cleaner assembly. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor 8 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2821 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The sensor is bolted to the cylinder block near the rear of the right cylinder head. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2822 Crankshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2823 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR 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. Sensor Operation The flywheel/drive plate has 8 single notches, spaced every 45 degrees, 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. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a crankshaft position sensor input. CRANKSHAFT POSITION SENSOR-PCM INPUT This sensor is a hall effect device that detects notches in the flywheel (manual transmission) or flexplate (automatic transmission). This sensor is used to indicate to the Powertrain Control Module (PCM) that a spark and or fuel injection event is to be required. The output from this sensor, in conjunction with the camshaft position sensor signal, is used to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2824 Crankshaft Position Sensor The sensor is bolted to the cylinder block near the rear of the right cylinder head. Refer to Ignition System for more crankshaft position sensor information. The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2825 Crankshaft Position Sensor: Testing and Inspection To perform a complete test of this sensor and its circuitry, refer to the DRB scan tool. Also refer to the appropriate Powertrain Diagnostics Procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2826 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. 1. Remove right front tire and right front wheelhouse liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheelhouse liner. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Cap Inspection - External - Typical Cap Inspection-Internal-Typical Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the inside (caused by condensation entering the cap through cracks). Replace any cap that displays charred or eroded terminals. The machined surface of a terminal end (faces toward rotor) will indicate some evidence of erosion from normal operation. Examine the terminal ends for evidence of mechanical interference with the rotor tip. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Rotor Inspection - Typical Visually inspect the rotor for cracks, evidence of corrosion or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on the end of the metal tip. The silicone-dielectric- varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2842 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2843 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2844 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2845 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2846 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2847 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 2853 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 2854 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 2855 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 2856 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 2857 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 2858 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 2859 Ignition Cable: Specifications Spark Plug Cable Resistance Minimum 250 ohms 3000 ohms Maximum 1000 ohms 12000 ohms Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 2860 Ignition Cable: Description and Operation Spark plug cables are sometimes referred to as secondary ignition wires. These cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 2861 Ignition Cable: Testing and Inspection Check the spark plug cable connections for good contact at the coil(s), distributor cap towers, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, distributor and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean high voltage ignition cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. Head Shields On all engines, spark plug cable heat shields are pressed into the cylinder head to surround each spark plug cable boot and spark plug. These shields protect the spark plug boots from damage (due to intense engine heat generated by the exhaust manifolds) and should not be removed. After the spark plug cable has been installed, the lip of the cable boot should have a small air gap to the top of the heat shield. Testing When testing secondary cables for damage with an oscilloscope, follow the instructions of the equipment manufacturer. If an oscilloscope is not available, spark plug cables may be tested as follows: CAUTION: Do not leave any one spark plug cable disconnected for longer than necessary during testing. This may cause possible heat damage to the catalytic converter. Total test time must not exceed ten minutes. With the engine running, remove spark plug cable from spark plug (one at a time) and hold next to a good engine ground. If the cable and spark plug are in good condition, the engine rpm should drop and the engine will run poorly. If engine rpm does not drop, the cable and/or spark plug may not be operating properly and should be replaced. Also check engine cylinder compression. With the engine not running, connect one end of a test probe to a good ground. Start the engine and run the other end of the test probe along the entire length of all spark plug cables. If cables are cracked or punctured, there will be a noticeable spark jump from the damaged area to the test probe. The cable running from the ignition coil to the distributor cap can be checked in the same manner. Cracked, damaged or faulty cables should be replaced with resistance type cable. This can be identified by the words ELECTRONIC SUPPRESSION printed on the cable jacket. Use an ohmmeter to test for open circuits, excessive resistance or loose terminals. If equipped, remove the distributor cap from the distributor. Do not remove cables from cap. Remove cable from spark plug. Connect ohmmeter to spark plug terminal end of cable and to corresponding electrode in distributor cap. Resistance should be 250 to 1000 Ohms per inch of cable. If not, remove cable from distributor cap tower and connect ohmmeter to the terminal ends of cable. If resistance is not within specifications as found in the SPARK PLUG CABLE RESISTANCE chart, replace the cable. Test all spark plug cables in this manner. SPARK PLUG CABLE RESISTANCE MINIMUM = MAXIMUM 250 Ohms Per Inch = 1000 Ohms Per Inch 3000 Ohms Per Foot = 12,000 Ohms Per Foot Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 2862 Ignition Cable: Service and Repair REMOVAL AND INSTALLATION Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. Engine Firing Order Install cables into the proper engine cylinder firing order. When replacing the spark plug and coil cables, route the cables correctly and secure in the proper retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause cross ignition of the plugs or short circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and the distributor cap tower. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications Ignition Coil: Electrical Specifications Coil Manufacturer Toyodenso Primary Resistance 0.95-1.20 ohms Secondary Resistance 11,300-13,300 ohms at 21-27 deg C Diamond Primary Resistance 0.97-1.18 ohms Secondary Resistance 11,300-15,300 ohms at 21-27 deg C Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications > Page 2867 Ignition Coil: Mechanical Specifications Ignition Coil Mounting (if nuts/bolts are used ) 11 Nm Ignition Coil Mounting (if tapped bolts are used ) 5 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2868 Ignition Coil: Locations Ignition Coil The ignition coil is located near the front of the right cylinder head. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2869 Ignition Coil Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2870 Ignition Coil: Service Precautions WARNING: DO NOT REMOVE THE COIL MOUNTING BRACKET-TO-CYLINDER HEAD MOUNTING BOLTS. THE COIL MOUNTING BRACKET IS UNDER ACCESSORY DRIVE BELT TENSION. IF THIS BRACKET IS TO BE REMOVED FOR ANY REASON, ALL BELT TENSION MUST FIRST BE RELIEVED. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2871 Ignition Coil: Description and Operation IGNITION COIL Battery voltage is supplied to the ignition coil positive terminal from the ASD relay. The Powertrain Control Module (PCM) opens and closes the ignition coil ground circuit for ignition coil operation. Base ignition timing is not adjustable on any engine. By controlling the coil ground circuit, the PCM is able to set the base timing and adjust the ignition timing advance. This is done to meet changing engine operating conditions. 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. IGNITION COIL-ENGINES-PCM OUTPUT System voltage is supplied to the ignition coil positive terminal. The Powertrain Control Module (PCM) operates the ignition coil. Base (initial) ignition timing is not adjustable. The PCM adjusts ignition timing to meet changing engine operating conditions. Ignition Coil The ignition coil is located near the front of the right cylinder head. Refer to Ignition System for additional information. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2872 Ignition Coil: Testing and Inspection To perform a complete test of the ignition coil and its circuitry, refer to the DRB scan tool. Also refer to the appropriate Powertrain Diagnostics Procedures. To test the coil only, refer to the following: Ignition Coil-Typical (5.2/5.9L) The ignition coil is designed to operate without an external ballast resistor. Inspect the ignition coil for arcing. Test the coil according to coil tester manufacturer's instructions. Test the coil primary and secondary resistance. Replace any coil that does not meet specifications. Refer to the IGNITION COIL RESISTANCE chart. IGNITION COIL RESISTANCE COIL MANUFACTURER = Diamond PRIMARY RESISTANCE 21 - 27° C (70-80° F) = 0.97 - 1.18 Ohms SECONDARY RESISTANCE 21 - 27° C (70-80° F) = 11,300-15,300 Ohms COIL MANUFACTURER = Toyodenso PRIMARY RESISTANCE 21 - 27° C (70-80° F) = 0.95 1.20 Ohms SECONDARY RESISTANCE 21 - 27° C (70-80° F) = 11,300-13,300 Ohms If the ignition coil is being replaced, the secondary spark plug cable must also be checked. Replace cable if it has been burned or damaged. Arcing at the tower will carbonize the cable boot, which if it is connected to a new ignition coil, will cause the coil to fail. If the secondary coil cable shows any signs of damage, it should be replaced with a new cable and new terminal. Carbon tracking on the old cable can cause arcing and the failure of a new ignition coil. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2873 Ignition Coil: Service and Repair The ignition coil is an epoxy filled type. If the coil is replaced, it must be replaced with the same type. REMOVAL Ignition Coil The coil is mounted to a bracket that is bolted to the front of the right engine cylinder head. This bracket is mounted on top of the automatic belt tensioner bracket using common bolts. 1. Disconnect the primary wiring from the ignition coil. 2. Disconnect the secondary spark plug cable from the ignition coil. WARNING: DO NOT REMOVE THE COIL MOUNTING BRACKET-TO-CYLINDER HEAD MOUNTING BOLTS. THE COIL MOUNTING BRACKET IS UNDER ACCESSORY DRIVE BELT TENSION. IF THIS BRACKET IS TO BE REMOVED FOR ANY REASON, ALL BELT TENSION MUST FIRST BE RELIEVED. 3. Remove ignition coil from coil mounting bracket (two bolts). INSTALLATION 1. Install the ignition coil to coil bracket. If nuts and bolts are used to secure coil to coil bracket, tighten to 11 Nm (100 in. lbs.) torque. If the coil mounting bracket has been tapped for coil mounting bolts, tighten bolts to 5 Nm (50 in. lbs.) torque. 2. Connect all wiring to ignition coil. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 2877 Ignition Relay: Diagrams Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 2878 Horn, Ignition (Max Cooling) & Trailer Tow Relays Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 2883 Ignition Relay: Diagrams Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 2884 Horn, Ignition (Max Cooling) & Trailer Tow Relays Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor Oil Pressure Sending Unit/Switch, Camshaft Position Sensor Connector The camshaft position sensor is located in the distributor on all engines. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2889 Camshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2890 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor CAMSHAFT POSITION SENSOR - PCM INPUT A sync signal is provide by the camshaft position sensor located in the distributor. The sync signal from this sensor works in conjunction with the crankshaft position sensor to provide the Powertrain Control Module (PCM) with inputs. This is done to establish and maintain correct injector firing order. CAMSHAFT POSITION SENSOR The camshaft position sensor is located in the distributor on all engines. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2891 Camshaft Position Sensor: Testing and Inspection Camshaft Position Sensor The camshaft position sensor is located in the distributor on all engines. To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the following: For this test, an analog (non-digital) voltmeter is needed. Do not remove the distributor connector from the distributor. Using small paper clips, insert them into the backside of the distributor wire harness connector to make contact with the terminals. Be sure that the connector is not damaged when inserting the paper clips. Attach voltmeter leads to these paper clips. 1. Connect the positive (+) voltmeter lead into the sensor output wire. This is at done the distributor wire harness connector. 2. Connect the negative (-) voltmeter lead into the ground wire. 3. Set the voltmeter to the 15 Volt DC scale. 4. Remove distributor cap from distributor (two screws). Rotate (crank) the engine until the distributor rotor is pointed towards the rear of vehicle. The movable pulse ring should now be within the sensor pickup. 5. Turn ignition key to ON position. Voltmeter should read approximately 5.0 volts. 6. If voltage is not present, check the voltmeter leads for a good connection. 7. If voltage is still not present, check for voltage at the supply wire. For wire identification, refer to Wiring Diagrams. 8. If 5 volts is not present at supply wire, check for voltage at PCM 32-way connector (cavity A-17). Leave the PCM connector connected for this test. 9. If voltage is still not present, perform vehicle test using the DRB scan tool. 10. If voltage is present at cavity A-17, but not at the supply wire: a. Check continuity between the supply wire. This is checked between the distributor connector and cavity A-17 at the PCM. If continuity is not present, repair the harness as necessary. b. Check for continuity between the camshaft position sensor output wire and cavity A-18 at the PCM, If continuity is not present, repair the harness as necessary. c. Check for continuity between the ground circuit wire at the distributor connector and ground. If continuity is not present, repair the harness as necessary. 11. While observing the voltmeter, crank the engine with ignition switch. The voltmeter needle should fluctuate between 0 and 5 volts while the engine is cranking. This verifies that the camshaft position sensor in the distributor is operating properly and a sync pulse signal is being generated. If sync pulse signal is not present, replacement of the camshaft position sensor is necessary Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2892 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor The camshaft position sensor is located in the distributor on all engines. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove air cleaner assembly. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. tighten mounting screws. 5. Install air cleaner assembly. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor 8 Nm Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2896 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The sensor is bolted to the cylinder block near the rear of the right cylinder head. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2897 Crankshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2898 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR 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. Sensor Operation The flywheel/drive plate has 8 single notches, spaced every 45 degrees, 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. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a crankshaft position sensor input. CRANKSHAFT POSITION SENSOR-PCM INPUT This sensor is a hall effect device that detects notches in the flywheel (manual transmission) or flexplate (automatic transmission). This sensor is used to indicate to the Powertrain Control Module (PCM) that a spark and or fuel injection event is to be required. The output from this sensor, in conjunction with the camshaft position sensor signal, is used to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2899 Crankshaft Position Sensor The sensor is bolted to the cylinder block near the rear of the right cylinder head. Refer to Ignition System for more crankshaft position sensor information. The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2900 Crankshaft Position Sensor: Testing and Inspection To perform a complete test of this sensor and its circuitry, refer to the DRB scan tool. Also refer to the appropriate Powertrain Diagnostics Procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2901 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. 1. Remove right front tire and right front wheelhouse liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheelhouse liner. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Removal/Installation. On vehicles equipped with an automatic transmission and a steering column mounted shifter an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced.. On vehicles equipped with an automatic transmission and a floor mounted shifter , a cable connects the interlock device within the steering column assembly, to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. The shifter interlock cable can be adjusted or replaced. SYSTEM DESCRIPTION The key-in ignition switch is integral to the ignition switch, which is mounted on the right side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition lock cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition lock cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 2906 Ignition Switch Lock Cylinder: Service and Repair The ignition key must be in the key cylinder for cylinder removal. REMOVAL 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. Shroud Removal/Installation - Typical 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Retaining Pin 5. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 2907 Flag In RUN Position Key Cylinder-Rear View Switch Mounting Screws 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 2908 Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed. 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Ignition Switch View From Column Park Lock Linkage-Automatic Transmission-Typical Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 2909 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkage before installing switch. Steering Wheel Lock Lever 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 3 Nm ± 0.5 Nm (26 in. lbs. ± 4 in. lbs.) torque. 11. Connect electrical connectors to ignition switch and halo lamp. Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). Tighten screws to 2 Nm (17 in. lbs.) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery. 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY; LOCK, OFF, ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify. Steering wheel should unlock when key is rotated to ON position. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap 0.040 in Torque 30 ft lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 2913 Spark Plug: Application and ID Plug Type ............................................................................................................................................ .................................................................... RC12LC4 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 2914 Spark Plug: Description and Operation All engines use resistor type spark plugs. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Spark plugs that have low milage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Refer to the Spark Plug Condition. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 2915 Spark Plug: Testing and Inspection SPARK PLUG CONDITIONS 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. Gap growth will not average more than approximately 0.025 mm (0.001 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. Oil Or Ash Encrusted Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 2916 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. 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. Scavenger Deposits Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but this is a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy, but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and can be cleaned using standard procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 2917 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. 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.) Spark Plug Overheating Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 2918 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 2919 Spark Plug: Service and Repair Heat Shields On all engines, spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. PLUG REMOVAL Cable Removal 1. Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result. 2. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. This will help prevent foreign material from entering the combustion chamber. 3. Remove the spark plug using a quality socket with a rubber or foam insert. 4. Inspect the spark plug condition. Refer to Spark Plug Condition in the Diagnostics and Testing. PLUG CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. PLUG GAP ADJUSTMENT Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 2920 Setting Spark Plug Gap - Typical Check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode. Never attempt to adjust the gap by bending the center electrode. SPARK PLUG GAP 1.01 mm (0.040 in) PLUG INSTALLATION Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 35-41 Nm (26-30 ft. lbs.) torque. 3. Install spark plug cables over spark plugs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: Customer Interest A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 2932 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 2938 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Component Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Component Locations > Page 2943 Output Shaft Speed Sensor, Park/Neutral Switch, Transmission Solenoid 8-Way Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 2944 Automatic Transmission Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 2945 Shift Solenoid: Description and Operation THREE-FOUR SHIFT SOLENOID-PCM OUTPUT This output is used to control the transmission three-four shift solenoid. It is used on 4-speed electronically controlled automatic transmissions only. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 2949 Automatic Transmission Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 2950 Torque Converter Clutch Solenoid: Description and Operation TORQUE CONVERTOR CLUTCH (TCC) SOLENOID-PCM OUTPUT This circuit controls operation of the transmission mounted torque convertor clutch (TCC) solenoid used for torque convertor engagement. The powertrain control module (PCM) will determine when to engage and disengage the solenoid by monitoring vehicle miles per hour (mph) versus the output voltage of the throttle position sensor. Also needed are various inputs from: Transmission temperature sensor - Output shaft speed sensor - Module timer - Engine rpm - MAP sensor - Brake switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation OVERDRIVE LAMP-PCM OUTPUT This circuit controls a signal for the operation of the push-button overdrive lamp switch. When the lamp is illuminated, the overdrive is disengaged. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 2959 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Service Precautions Four-Wheel Drive (4WD) Indicator Lamp: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Service Precautions > Page 2964 Four-Wheel Drive (4WD) Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Four Wheel Drive Lamp ....................................................................................................................... ................................................................. 161 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Testing and Inspection > Four-Wheel Drive Indicator Lamp - Full Time Four-Wheel Drive (4WD) Indicator Lamp: Testing and Inspection Four-Wheel Drive Indicator Lamp - Full Time HARD-WIRED LAMP DIAGNOSIS This lamp depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedure will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS (SUPPLEMENTAL 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. FOUR-WHEEL DRIVE INDICATOR LAMP - FULL TIME The diagnosis found here addresses an inoperative four-wheel drive indicator lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or switch and not with a damaged or inoperative transfer case or transfer case linkage. Refer to Transmission and Drivetrain/Transfer Case/NV242 Diagnosis for more information. If no transfer case problem is found, the following procedure will help locate a short or open in the indicator lamp circuit. For complete circuit diagrams, refer to Complete Body and Chassis Diagrams, See: Diagrams/Electrical Diagrams/Diagrams By Group Number 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. Disconnect the transfer case switch wire harness connector. Check for continuity between the ground circuit cavity of the transfer case 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. Connect the battery negative cable. Turn the ignition switch to the ON position. Install a jumper wire between the full time four wheel drive indicator lamp driver circuit cavity of the transfer case switch wire harness connector and a good ground. The full time four-wheel drive indicator lamp should light. If OK, replace the faulty transfer case switch. 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 cluster. With the transfer case switch wire harness connector still disconnected, check for continuity between the full time four wheel drive indicator lamp driver circuit cavity of the instrument cluster wire harness connector A and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted full time four wheel drive indicator lamp driver circuit as required. 6. Check for continuity between the full time four wheel drive indicator lamp driver circuit cavities of the instrument cluster wire harness connector A and the transfer case switch wire harness connector. There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open full time four wheel drive indicator lamp driver circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Testing and Inspection > Four-Wheel Drive Indicator Lamp - Full Time > Page 2967 Four-Wheel Drive (4WD) Indicator Lamp: Testing and Inspection Four-Wheel Drive Indicator Lamp - Part Time HARD-WIRED LAMP DIAGNOSIS This lamp depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedure will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS (SUPPLEMENTAL 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. FOUR-WHEEL DRIVE INDICATOR LAMP - PART TIME The diagnosis found here addresses an inoperative four-wheel drive indicator lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or switch and not with a damaged or inoperative transfer case or transfer case linkage. Refer to Transmission and Drivetrain/Transfer Case/NV231 Diagnosis or NV242 Diagnosis for more information. If no transfer case problem is found, the following procedure will help locate a short or open in the indicator lamp circuit. For complete circuit diagrams, refer to Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number 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. Disconnect the transfer case switch wire harness connector. Check for continuity between the ground circuit cavity of the transfer case 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. Connect the battery negative cable. Turn the ignition switch to the ON position. Install a jumper wire between the part time four wheel drive indicator lamp driver circuit cavity of the transfer case switch wire harness connector and a good ground. The part time four-wheel drive indicator lamp should light. If OK, replace the faulty transfer case switch. If not OK, go to Step 5. 5. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector at the Controller Anti-Lock Brake (CAB). Remove the instrument cluster. With the transfer case switch wire harness connector still disconnected, check for continuity between the part time four wheel drive indicator lamp driver circuit cavity of the instrument cluster wire harness connector B and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted part time four wheel drive indicator lamp driver circuit as required. 6. Check for continuity between the part time four wheel drive indicator lamp driver circuit cavities of the instrument cluster wire harness connector B and the transfer case switch wire harness connector. There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open part time four wheel drive indicator lamp driver circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2978 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2979 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2985 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2986 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 24-013-01 > Sep > 01 > A/C - Warm Air From Vents at Idle Condenser Fan: All Technical Service Bulletins A/C - Warm Air From Vents at Idle NUMBER: 24-013-01 GROUP: Heating & A/C DATE: September 28, 2001 SUBJECT: Warm air blows from panel outlets with A/C on at idle. OVERVIEW: This bulletin involves installing an electric cooling fan kit. MODELS: 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES NOT EQUIPPED WITH DAYTIME RUNNING LAMPS. SYMPTOM/CONDITION: Some 1998 - 1999 (DN) Durangos may blow warm air out the instrument panel outlets while the A/C is ON in conditions of ambient temperatures exceeding 30° C. (86° F.) and the vehicle not in motion. In conditions of "stop-and-go" traffic or while idling in high ambient temperatures, the A/C high side pressures may exceed the high-pressure switch shut off of 450 - 490 psi. causing the A/C compressor to disengage. The compressor will re-engage once the high side pressure drops below 270 - 330 psi. The root cause of the problem may be related to inadequate airflow through the A/C condenser in high ambient temperatures while the vehicle is not in motion. DIAGNOSIS: NOTE: THIS PROCEDURE WILL NOT CORRECT A CONDITION WHERE THE A/C COMPRESSOR DISENGAGES DUE TO EXCESSIVE HIGH SIDE PRESSURE WHILE THE VEHICLE IS IN MOTION. NOR WILL THIS PROCEDURE CORRECT ANY A/C PERFORMANCE COMPLAINT OTHER THAN THE LOSS OF A/C IN "STOP-AND-GO" TRAFFIC OR IDLE CONDITIONS WHILE IN HIGH AMBIENT TEMPERATURES AND HUMIDITY. Verify A/C system operation by performing an A/C Performance Test. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), pages 24-13 through 24-16. If the vehicle passes the A/C performance test as identified in the 1999 Durango Service Manual, yet the customer complains that warm air discharges out the panel ducts with the A/C ON with the vehicle NOT in motion, install the Electric Cooling Fan Kit. If the vehicle did not pass the performance test, repair the vehicle as necessary. This procedure WILL NOT be able to correct the condition. PARTS REQUIRED: NOTE: DUE TO THE ELECTRICAL LOAD REQUIREMENTS OF THE ELECTRIC COOLING FAN, THE 136 AMP GENERATOR IS REQUIRED ON ALL VEHICLES. SOME 1999 MODELS MAY HAVE THE 136 AMP GENERATOR. 1999 MODELS EQUIPPED WITH TRAILER TOW PACKAGE (SALES CODE AHC) ARE EQUIPPED WITH THE 136 AMP GENERATOR. TO ENSURE THAT 1999 MODELS ARE EQUIPPED WITH THE 136 AMP GENERATOR, VERIFY THAT THE PART NUMBER ON THE GENERATOR IS 56028920AA. ALL MODELS NOT EQUIPPED WITH THE 136 AMP GENERATOR MUST USE KIT 05019227AB. REPAIR PROCEDURE: Detailed instructions are included in the parts kit. Refer to the instructions for the Repair Procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 24-013-01 > Sep > 01 > A/C - Warm Air From Vents at Idle > Page 2992 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 24-013-01 > Sep > 01 > A/C - Warm Air From Vents at Idle > Page 2998 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 2999 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 The Transmission Relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3003 Transmission Control System Relay: Diagrams Transmission Control Relay Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3004 Transmission Control & Wiper Relays And C106 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3005 Transmission Control System Relay: Description and Operation TRANSMISSION RELAY-PCM OUTPUT The output to this relay provides battery voltage to the overdrive (OD), torque converter clutch (TCC) and governor pressure solenoids. Once battery voltage is applied to the solenoids, they are individually activated by the PCM through OD, TCC and governor pressure outputs. The relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Overdrive Cancel Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3011 Automatic Transmission Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3012 Overdrive Switch: Description and Operation OVERDRIVE/OVERRIDE SWITCH-PCM INPUT On vehicles equipped with an automatic transmission and overdrive, the powertrain control module (PCM) regulates the 3-4 overdrive up-shift and downshift through the overdrive solenoid. This solenoid is located in the transmission. An overdrive/override push-button switch is located at the end of transmission shift lever. The overdrive/override push-button switch is normally open (overdrive allowed) when the lamp is not illuminated. It momentarily closes (overdrive not allowed) when the operator presses the switch and the lamp is illuminated. Overdrive will revert to ON (lamp off) each time the ignition switch in turned on. The transmission downshifts if the operator presses the override switch while in overdrive. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3016 Transmission Position Switch/Sensor: Description and Operation TRANSMISSION PARK/NEUTRAL SWITCH-PCM INPUT The park/neutral switch is located on the transmission housing and provides an input to the Powertrain Control Module (PCM), This will indicate that the automatic transmission is in Park, Neutral or a drive gear selection. This input is used to determine idle speed (varying with gear selection), fuel injector pulse width, ignition timing advance and vehicle speed control operation. The center terminal of the park/neutral position switch is the starter-circuit terminal. It provides the ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. The outer terminals on the switch are for the backup lamp circuit. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3017 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Transmission Speed Sensor: Specifications Sensor Mounting ................................................................................................................................. ..................................................... 27 Nm (20 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3021 Output Shaft Speed Sensor, Park/Neutral Switch, Transmission Solenoid 8-Way Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3022 Output Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input Transmission Speed Sensor: Description and Operation Output Shaft Speed Sensor-PCM Input This sensor generates a signal to the PCM relating to the speed of the transmission main drive shaft. NOTE: This input is used with 4-speed electronic transmissions only. CIRCUIT OPERATION Four Speed Automatic Transmission The output shaft speed sensor generates a signal indicating the speed of the transmission output shaft. Circuits T13 and T14 connect the sensor to the Powertrain Control Module (PCM). Circuit T13 connects to cavity B25 of the PCM. Circuit T14 connects to cavity B28. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input > Page 3025 Transmission Speed Sensor: Description and Operation Sensor Operation The speed sensor is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. The vehicle speed sensor also serves as a backup for the transmission speed sensor. Signals from this sensor are shared with the powertrain control module. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 3026 Transmission Speed Sensor: Service and Repair Removal Transmission Speed Sensor Removal Installation 1. Remove transmission speed sensor and O-ring seal from overdrive case. Installation 1. Install transmission speed sensor and O-ring seal in overdrive case. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3030 Transmission Temperature Sensor/Switch: Description and Operation TRANSMISSION TEMPERATURE SENSOR-PCM INPUT This input is used in the shift operation for 4-speed electronic transmissions only. The temperature data is used for: torque converter clutch operation, overdrive shift, low temperature shift compensation, wide open throttle shift strategy and governor pressure transducer calibration. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Locations 4WD Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Diagrams > 231 Transfer Case Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Diagrams > 231 Transfer Case > Page 3037 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications Gear Sensor/Switch: Specifications TIGHTENING SPECIFICATIONS Switch, Indicator .................................................................................................................................. .......................................................... 15-25 ft. lbs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-02 > Jun > 02 > Emissions - ASM Test Failure PROM - Programmable Read Only Memory: Customer Interest Emissions - ASM Test Failure NUMBER: 18-018-02 GROUP: Vehicle Performance DATE: June 10, 2002 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE MDS2 MUST BE OPERATING WITH CIS CD2III OR HIGHER, AVAILABLE JULY 8, 2002. SUBJECT: Flash: NOx Emission Failure When Performing an ASM Type I/M Emission Test OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (98Cal12E, 99Cal19E). MODELS: 1998-1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 5.2L ENGINE AND HAVE A CALIBRATION PRIOR TO THOSE LISTED ABOVE. DISCUSSION: Some states have implemented an Acceleration Simulation Mode (ASM) type of vehicle emissions test for the I/M (inspection/maintenance) testing programs. This test may fail the above models for NOx emissions. If a customer brings their vehicle in due to this failure, and no Diagnostic Trouble Codes (DTC's) or other reasons are found for this failure, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Connect a battery charger and set as close to a 14 volts charge as possible 2. Flash the PCM using the MDS2 (Mopar Diagnostic System) and DRBIII(R). NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (TCM, 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-02 > Jun > 02 > Emissions - ASM Test Failure > Page 3049 3. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and/or TCM as necessary and cover the label(s) with the clear plastic overlay. 4. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-004-02 > Jan > 02 > Engine - Spark Knock On Acceleration PROM - Programmable Read Only Memory: Customer Interest Engine - Spark Knock On Acceleration NUMBER: 18-004-02 GROUP: Vehicle Performance DATE: Jan. 28, 2002 THIS BULLETIN SUPERCEDES TECHNICAL SERVICE BULLETIN 18-06-00 REV C, DATED DEC 01, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE MDS2 MUST BE OPERATING WITH CIS CD2099 OR HIGHER. SUBJECT: 1999 M.Y. Engine Spark Knock OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 99Cal16B, 99Cal17, and 99Cal17A) MODELS: 1999 (AB) Ram Van 1999 (AN) Dakota 1999 (BR/BE) Ram Truck 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.9L (EHC), 5.2L (ELF), OR 5.9L LIGHT DUTY (EML) GASOLINE ENGINE. THERE ARE CERTAIN EXCEPTIONS. SEE THE TABLE FOR SPECIFIC EXCLUSIONS. NOTE: THIS BULLETIN DOES NOT APPLY TO THE FOLLOWING SPECIFIC VEHICLES WHEN EQUIPPED AS LISTED IN THE TABLE. THE PCM CALIBRATION SOFTWARE OF ANY EXCLUDED VEHICLE IS NOT TO BE REPROGRAMMED FOR A SPARK KNOCK COMPLAINT. BEFORE ATTEMPTING A REPROGRAMMING SESSION, INSPECT THE VEHICLE, TYPE, ENGINE, TRANSMISSION, AND EMISSIONS CATEGORY FOR POSSIBLE EXCLUSION. SYMPTOM/CONDITION: Some vehicle engines may exhibit a light-to-moderate spark knock condition during acceleration (under load). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-004-02 > Jan > 02 > Engine - Spark Knock On Acceleration > Page 3054 DIAGNOSIS PROCEDURES: 1. Verify that the following NOTE(S) have been reviewed and completed as necessary. 2. Verify that the engine coolant contains a quality antifreeze. The coolant mixture should consist of 44% to 68% antifreeze. 3. If the only condition seen is the light-to-moderate engine spark knock, then perform the Repair Procedure. NOTE: VERIFY THAT TSB 18-48-98, FOR ENGINE IGNITION WIRE ROUTING, HAS BEEN COMPLETED. NOTE: THIS REPAIR PROCEDURE WILL NOT COMPENSATE FOR HEAVY SPARK KNOCK CONDITIONS. IF HEAVY KNOCK IS EXPERIENCED, FURTHER DIAGNOSIS AND TESTING OF THE ENGINE WILL BE REQUIRED. REFER TO TSB 09-05-00 FOR ADDITIONAL ASSISTANCE. 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: REPAIR PROCEDURE: 1. Flash the PCM using the MDS2 (Mopar Diagnostic System) and the DRB III (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 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-004-02 > Jan > 02 > Engine - Spark Knock On Acceleration > Page 3055 2. Type the necessary information on the "Authorized Software Update Label" p/fl 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-25-99 > Nov > 99 > PCM - Erroneous Engine Misfire PROM - Programmable Read Only Memory: Customer Interest PCM - Erroneous Engine Misfire NUMBER: 18-25-99 GROUP: Vehicle Performance EFFECTIVE DATE: Nov. 15, 1999 SUBJECT: Erroneous Engine Miss While Performing Diagnostics With The DRB III OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 99Cal18, 99Cal17, or 99Cal16). MODELS: 1999 (AB) Ram Van 1999 (AN) Dakota 1999 (BR/BE) Ram Truck 1999 (DN) Durango 1999 (TJ) Wrangler 1999 (XJ) Cherokee 1999 (WJ) Grand Cherokee SYMPTOM/CONDITION: A Powertrain Control Module (PCM) software condition exists that can cause an erroneous engine miss to occur only when in certain screens of the Diagnostic Scan Tool (DRB III). The miss will not set a Malfunction Indicator Lamp (MIL), but may be felt and can be seen while performing diagnostics with the DRB III. This condition occurs only when using the DRB III to read Diagnostic Trouble Codes (DTC's), Secondary Indicators, or 1 Trip Failures and while driving the vehicle. This is more likely to occur during hard acceleration. While in these screens, a miss may be felt by the technician, or when in the Secondary Indicators or 1 Trip Failures screen an erroneous injector circuit failure can flash on the DRB III screen with an accompany beep from the DRB III. This condition may lead technicians to incorrectly diagnose a problem and may cause erroneous repairs that will not fix the vehicle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the DRB III with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If DTC's are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III THE SYSTEM MUST BE OPERATING AT CIS CD 2045 OR HIGHER. REPAIR PROCEDURE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-25-99 > Nov > 99 > PCM - Erroneous Engine Misfire > Page 3060 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-25-99 > Nov > 99 > PCM - Erroneous Engine Misfire > Page 3061 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-96 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-35-98 > Dec > 98 > PCM - False Mil ON, DTC P0443 Set PROM - Programmable Read Only Memory: Customer Interest PCM - False Mil ON, DTC P0443 Set NO: 18-35-98 GROUP: Vehicle Performance DATE: Dec. 18, 1998 SUBJECT: Erroneous MIL Illumination With DTC $12 (PO443) - Evap Purge Solenoid Circuit MODELS: 1999 (AB) Ram Van 1999 (AN) Dakota 1999 (BR/BE) Ram Truck 1999 (DN) Durango 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1999 (XJ) Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINES BUILT PRIOR TO DEC. 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit MIL illumination with DTC $12 (P0443) - EVAPORATIVE PURGE SOLENOID CIRCUIT FAILURE. This condition can be caused by electrical noise generated by the ignition switch. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. Following the Diagnostic Procedures Manual, check the evaporative purge solenoid and circuit for proper operation. If no trouble is found, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1175 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This procedure involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (99cal14 calibration change). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 CONNECT TO MDS 1 OR MDS 2 on the DRB III(R) MAIN MENU Screen. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-35-98 > Dec > 98 > PCM - False Mil ON, DTC P0443 Set > Page 3066 3. Select # 1 MDS DIAGNOSTICS OR DRB UPDATE on the DRB III(R). 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III(R) on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III(R) will prompt for any operator action needed during the remainder of the programming process. NOTE: XJ VEHICLES EQUIPPED WITH AN AISIN WARNER TRANSMISSION MAY SET DTC $BE (CCD MESSAGE FROM JTEC FAILURE) WITHIN THE TCM BECAUSE OF THE FLASH PROCEDURE AND THE DTC LOGGED IN THE TCM MAY SET DTC $89 (TCM CONTROLLER DTC PRESENT) WITHIN THE PCM. CHECK FOR AND ERASE THESE DTC'S PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-92 0.5 Hrs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-35-98 > Dec > 98 > PCM - False Mil ON, DTC P0443 Set > Page 3067 FAILURE CODE: FM - Flash Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-36-98 > Dec > 98 > PCM - Start and Stall, Idle Undershoot/Lost IAC Steps PROM - Programmable Read Only Memory: Customer Interest PCM - Start and Stall, Idle Undershoot/Lost IAC Steps NO: 18-36-98 GROUP: Vehicle Performance DATE: Dec. 18, 1998 SUBJECT: Start And Stall, Idle Undershoot - Lost Idle Air Control (IAC) Steps MODELS: 1999 (AB) Ram Van 1999 (AN) Dakota 1999 (BR/BE) Ram Truck 1999 (DN) Durango 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1999 (XJ) Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINES BUILT PRIOR TO DEC. 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit an idle undershoot or die out during engine starting and may be caused by IAC lost steps. This condition is more likely to occur during cold weather, low battery voltage, cold engine start, and quick ignition key "On" - "Off" operation. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no other problems are found, perform the Repair. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1175 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This procedure involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (99cal14 calibration change). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 CONNECT TO MDS 1 OR MDS 2 on the DRB III(R) MAIN MENU Screen. 3. Select # 1 MDS DIAGNOSTICS OR DRB UPDATE on the DRB III(R). 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-36-98 > Dec > 98 > PCM - Start and Stall, Idle Undershoot/Lost IAC Steps > Page 3072 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III(R) on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III(R) will prompt for any operator action needed during the remainder of the programming process. NOTE: XJ VEHICLES EQUIPPED WITH AN AISIN WARNER TRANSMISSION MAY SET DTC $BE (CCD MESSAGE FROM JTEC FAILURE) WITHIN THE TCM BECAUSE OF THE FLASH PROCEDURE AND THE DTC LOGGED IN THE TCM MAY SET DTC $89 (TCM CONTROLLER DTC PRESENT) WITHIN THE PCM. CHECK FOR AND ERASE THESE DTC'S PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-92 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-37-98 > Dec > 98 > PCM - Addition of A Clear Flood Feature PROM - Programmable Read Only Memory: Customer Interest PCM - Addition of A Clear Flood Feature NO: 18-37-98 GROUP: Vehicle Performance DATE: Dec. 18, 1998 SUBJECT: Addition Of A Clear Flood Feature MODELS: 1999 (AB) Ram Van 1999 (AN) Dakota 1999 (BR/BE) Ram Truck 1999 (DN) Durango 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1999 (XJ) Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINES BUILT PRIOR TO DEC. 18, 1998 (MDH 1218XX). DISCUSSION: Some customers that inadvertently flood their engines during starting may try to perform a clear flood (WOT) procedure to help start their vehicle. Currently this feature is not operational on the above models and if used may worsen the flooded condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present and the vehicle was brought in for a flooded condition, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 04669020 Label Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1175 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This procedure involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (99cal14 calibration change). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 CONNECT TO MDS 1 OR MDS 2 on the DRB III(R) MAIN MENU Screen. 3. Select # 1 MDS DIAGNOSTICS OR DRB UPDATE on the DRB III(R). 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-37-98 > Dec > 98 > PCM - Addition of A Clear Flood Feature > Page 3077 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III(R) on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III(R) will prompt for any operator action needed during the remainder of the programming process. NOTE: XJ VEHICLES EQUIPPED WITH AN AISIN WARNER TRANSMISSION MAY SET DTC $BE (CCD MESSAGE FROM JTEC FAILURE) WITHIN THE TCM BECAUSE OF THE FLASH PROCEDURE AND THE DTC LOGGED IN THE TCM MAY SET DTC $89 (TCM CONTROLLER DTC PRESENT) WITHIN THE PCM. CHECK FOR AND ERASE THESE DTC'S PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-92 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3082 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3083 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3084 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3090 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3091 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3092 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3093 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3094 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3095 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3096 ^ 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3097 ^ 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3098 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3099 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3100 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3101 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3102 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3103 ^ 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3104 ^ 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3105 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3106 ^ 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3107 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3108 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 18-018-02 > Jun > 02 > Emissions - ASM Test Failure PROM - Programmable Read Only Memory: All Technical Service Bulletins Emissions - ASM Test Failure NUMBER: 18-018-02 GROUP: Vehicle Performance DATE: June 10, 2002 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE MDS2 MUST BE OPERATING WITH CIS CD2III OR HIGHER, AVAILABLE JULY 8, 2002. SUBJECT: Flash: NOx Emission Failure When Performing an ASM Type I/M Emission Test OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (98Cal12E, 99Cal19E). MODELS: 1998-1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 5.2L ENGINE AND HAVE A CALIBRATION PRIOR TO THOSE LISTED ABOVE. DISCUSSION: Some states have implemented an Acceleration Simulation Mode (ASM) type of vehicle emissions test for the I/M (inspection/maintenance) testing programs. This test may fail the above models for NOx emissions. If a customer brings their vehicle in due to this failure, and no Diagnostic Trouble Codes (DTC's) or other reasons are found for this failure, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Connect a battery charger and set as close to a 14 volts charge as possible 2. Flash the PCM using the MDS2 (Mopar Diagnostic System) and DRBIII(R). NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (TCM, 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 18-018-02 > Jun > 02 > Emissions - ASM Test Failure > Page 3113 3. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and/or TCM as necessary and cover the label(s) with the clear plastic overlay. 4. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 18-004-02 > Jan > 02 > Engine - Spark Knock On Acceleration PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Spark Knock On Acceleration NUMBER: 18-004-02 GROUP: Vehicle Performance DATE: Jan. 28, 2002 THIS BULLETIN SUPERCEDES TECHNICAL SERVICE BULLETIN 18-06-00 REV C, DATED DEC 01, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE MDS2 MUST BE OPERATING WITH CIS CD2099 OR HIGHER. SUBJECT: 1999 M.Y. Engine Spark Knock OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 99Cal16B, 99Cal17, and 99Cal17A) MODELS: 1999 (AB) Ram Van 1999 (AN) Dakota 1999 (BR/BE) Ram Truck 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.9L (EHC), 5.2L (ELF), OR 5.9L LIGHT DUTY (EML) GASOLINE ENGINE. THERE ARE CERTAIN EXCEPTIONS. SEE THE TABLE FOR SPECIFIC EXCLUSIONS. NOTE: THIS BULLETIN DOES NOT APPLY TO THE FOLLOWING SPECIFIC VEHICLES WHEN EQUIPPED AS LISTED IN THE TABLE. THE PCM CALIBRATION SOFTWARE OF ANY EXCLUDED VEHICLE IS NOT TO BE REPROGRAMMED FOR A SPARK KNOCK COMPLAINT. BEFORE ATTEMPTING A REPROGRAMMING SESSION, INSPECT THE VEHICLE, TYPE, ENGINE, TRANSMISSION, AND EMISSIONS CATEGORY FOR POSSIBLE EXCLUSION. SYMPTOM/CONDITION: Some vehicle engines may exhibit a light-to-moderate spark knock condition during acceleration (under load). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 18-004-02 > Jan > 02 > Engine - Spark Knock On Acceleration > Page 3118 DIAGNOSIS PROCEDURES: 1. Verify that the following NOTE(S) have been reviewed and completed as necessary. 2. Verify that the engine coolant contains a quality antifreeze. The coolant mixture should consist of 44% to 68% antifreeze. 3. If the only condition seen is the light-to-moderate engine spark knock, then perform the Repair Procedure. NOTE: VERIFY THAT TSB 18-48-98, FOR ENGINE IGNITION WIRE ROUTING, HAS BEEN COMPLETED. NOTE: THIS REPAIR PROCEDURE WILL NOT COMPENSATE FOR HEAVY SPARK KNOCK CONDITIONS. IF HEAVY KNOCK IS EXPERIENCED, FURTHER DIAGNOSIS AND TESTING OF THE ENGINE WILL BE REQUIRED. REFER TO TSB 09-05-00 FOR ADDITIONAL ASSISTANCE. 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: REPAIR PROCEDURE: 1. Flash the PCM using the MDS2 (Mopar Diagnostic System) and the DRB III (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 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 18-004-02 > Jan > 02 > Engine - Spark Knock On Acceleration > Page 3119 2. Type the necessary information on the "Authorized Software Update Label" p/fl 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 18-25-99 > Nov > 99 > PCM - Erroneous Engine Misfire PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Erroneous Engine Misfire NUMBER: 18-25-99 GROUP: Vehicle Performance EFFECTIVE DATE: Nov. 15, 1999 SUBJECT: Erroneous Engine Miss While Performing Diagnostics With The DRB III OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 99Cal18, 99Cal17, or 99Cal16). MODELS: 1999 (AB) Ram Van 1999 (AN) Dakota 1999 (BR/BE) Ram Truck 1999 (DN) Durango 1999 (TJ) Wrangler 1999 (XJ) Cherokee 1999 (WJ) Grand Cherokee SYMPTOM/CONDITION: A Powertrain Control Module (PCM) software condition exists that can cause an erroneous engine miss to occur only when in certain screens of the Diagnostic Scan Tool (DRB III). The miss will not set a Malfunction Indicator Lamp (MIL), but may be felt and can be seen while performing diagnostics with the DRB III. This condition occurs only when using the DRB III to read Diagnostic Trouble Codes (DTC's), Secondary Indicators, or 1 Trip Failures and while driving the vehicle. This is more likely to occur during hard acceleration. While in these screens, a miss may be felt by the technician, or when in the Secondary Indicators or 1 Trip Failures screen an erroneous injector circuit failure can flash on the DRB III screen with an accompany beep from the DRB III. This condition may lead technicians to incorrectly diagnose a problem and may cause erroneous repairs that will not fix the vehicle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the DRB III with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If DTC's are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III THE SYSTEM MUST BE OPERATING AT CIS CD 2045 OR HIGHER. REPAIR PROCEDURE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 18-25-99 > Nov > 99 > PCM - Erroneous Engine Misfire > Page 3124 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 18-25-99 > Nov > 99 > PCM - Erroneous Engine Misfire > Page 3125 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-96 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 18-35-98 > Dec > 98 > PCM - False Mil ON, DTC P0443 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - False Mil ON, DTC P0443 Set NO: 18-35-98 GROUP: Vehicle Performance DATE: Dec. 18, 1998 SUBJECT: Erroneous MIL Illumination With DTC $12 (PO443) - Evap Purge Solenoid Circuit MODELS: 1999 (AB) Ram Van 1999 (AN) Dakota 1999 (BR/BE) Ram Truck 1999 (DN) Durango 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1999 (XJ) Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINES BUILT PRIOR TO DEC. 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit MIL illumination with DTC $12 (P0443) - EVAPORATIVE PURGE SOLENOID CIRCUIT FAILURE. This condition can be caused by electrical noise generated by the ignition switch. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. Following the Diagnostic Procedures Manual, check the evaporative purge solenoid and circuit for proper operation. If no trouble is found, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1175 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This procedure involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (99cal14 calibration change). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 CONNECT TO MDS 1 OR MDS 2 on the DRB III(R) MAIN MENU Screen. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 18-35-98 > Dec > 98 > PCM - False Mil ON, DTC P0443 Set > Page 3130 3. Select # 1 MDS DIAGNOSTICS OR DRB UPDATE on the DRB III(R). 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III(R) on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III(R) will prompt for any operator action needed during the remainder of the programming process. NOTE: XJ VEHICLES EQUIPPED WITH AN AISIN WARNER TRANSMISSION MAY SET DTC $BE (CCD MESSAGE FROM JTEC FAILURE) WITHIN THE TCM BECAUSE OF THE FLASH PROCEDURE AND THE DTC LOGGED IN THE TCM MAY SET DTC $89 (TCM CONTROLLER DTC PRESENT) WITHIN THE PCM. CHECK FOR AND ERASE THESE DTC'S PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-92 0.5 Hrs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 18-35-98 > Dec > 98 > PCM - False Mil ON, DTC P0443 Set > Page 3131 FAILURE CODE: FM - Flash Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 18-36-98 > Dec > 98 > PCM - Start and Stall, Idle Undershoot/Lost IAC Steps PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Start and Stall, Idle Undershoot/Lost IAC Steps NO: 18-36-98 GROUP: Vehicle Performance DATE: Dec. 18, 1998 SUBJECT: Start And Stall, Idle Undershoot - Lost Idle Air Control (IAC) Steps MODELS: 1999 (AB) Ram Van 1999 (AN) Dakota 1999 (BR/BE) Ram Truck 1999 (DN) Durango 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1999 (XJ) Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINES BUILT PRIOR TO DEC. 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit an idle undershoot or die out during engine starting and may be caused by IAC lost steps. This condition is more likely to occur during cold weather, low battery voltage, cold engine start, and quick ignition key "On" - "Off" operation. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no other problems are found, perform the Repair. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1175 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This procedure involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (99cal14 calibration change). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 CONNECT TO MDS 1 OR MDS 2 on the DRB III(R) MAIN MENU Screen. 3. Select # 1 MDS DIAGNOSTICS OR DRB UPDATE on the DRB III(R). 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 18-36-98 > Dec > 98 > PCM - Start and Stall, Idle Undershoot/Lost IAC Steps > Page 3136 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III(R) on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III(R) will prompt for any operator action needed during the remainder of the programming process. NOTE: XJ VEHICLES EQUIPPED WITH AN AISIN WARNER TRANSMISSION MAY SET DTC $BE (CCD MESSAGE FROM JTEC FAILURE) WITHIN THE TCM BECAUSE OF THE FLASH PROCEDURE AND THE DTC LOGGED IN THE TCM MAY SET DTC $89 (TCM CONTROLLER DTC PRESENT) WITHIN THE PCM. CHECK FOR AND ERASE THESE DTC'S PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-92 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 18-37-98 > Dec > 98 > PCM - Addition of A Clear Flood Feature PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Addition of A Clear Flood Feature NO: 18-37-98 GROUP: Vehicle Performance DATE: Dec. 18, 1998 SUBJECT: Addition Of A Clear Flood Feature MODELS: 1999 (AB) Ram Van 1999 (AN) Dakota 1999 (BR/BE) Ram Truck 1999 (DN) Durango 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1999 (XJ) Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINES BUILT PRIOR TO DEC. 18, 1998 (MDH 1218XX). DISCUSSION: Some customers that inadvertently flood their engines during starting may try to perform a clear flood (WOT) procedure to help start their vehicle. Currently this feature is not operational on the above models and if used may worsen the flooded condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present and the vehicle was brought in for a flooded condition, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 04669020 Label Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1175 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This procedure involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (99cal14 calibration change). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 CONNECT TO MDS 1 OR MDS 2 on the DRB III(R) MAIN MENU Screen. 3. Select # 1 MDS DIAGNOSTICS OR DRB UPDATE on the DRB III(R). 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 18-37-98 > Dec > 98 > PCM - Addition of A Clear Flood Feature > Page 3141 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III(R) on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III(R) will prompt for any operator action needed during the remainder of the programming process. NOTE: XJ VEHICLES EQUIPPED WITH AN AISIN WARNER TRANSMISSION MAY SET DTC $BE (CCD MESSAGE FROM JTEC FAILURE) WITHIN THE TCM BECAUSE OF THE FLASH PROCEDURE AND THE DTC LOGGED IN THE TCM MAY SET DTC $89 (TCM CONTROLLER DTC PRESENT) WITHIN THE PCM. CHECK FOR AND ERASE THESE DTC'S PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-92 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3146 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3147 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3148 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3154 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3155 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3156 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3157 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3158 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3159 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3160 ^ 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3161 ^ 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3162 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3163 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3164 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3165 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3166 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3167 ^ 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3168 ^ 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3169 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3170 ^ 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3171 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3172 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: Customer Interest A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3184 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3190 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Component Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Component Locations > Page 3195 Output Shaft Speed Sensor, Park/Neutral Switch, Transmission Solenoid 8-Way Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3196 Automatic Transmission Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3197 Shift Solenoid: Description and Operation THREE-FOUR SHIFT SOLENOID-PCM OUTPUT This output is used to control the transmission three-four shift solenoid. It is used on 4-speed electronically controlled automatic transmissions only. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3201 Automatic Transmission Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3202 Torque Converter Clutch Solenoid: Description and Operation TORQUE CONVERTOR CLUTCH (TCC) SOLENOID-PCM OUTPUT This circuit controls operation of the transmission mounted torque convertor clutch (TCC) solenoid used for torque convertor engagement. The powertrain control module (PCM) will determine when to engage and disengage the solenoid by monitoring vehicle miles per hour (mph) versus the output voltage of the throttle position sensor. Also needed are various inputs from: Transmission temperature sensor - Output shaft speed sensor - Module timer - Engine rpm - MAP sensor - Brake switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: Customer Interest A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3213 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3219 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Component Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Component Locations > Page 3224 Output Shaft Speed Sensor, Park/Neutral Switch, Transmission Solenoid 8-Way Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3225 Automatic Transmission Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3226 Shift Solenoid: Description and Operation THREE-FOUR SHIFT SOLENOID-PCM OUTPUT This output is used to control the transmission three-four shift solenoid. It is used on 4-speed electronically controlled automatic transmissions only. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3230 Automatic Transmission Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3231 Torque Converter Clutch Solenoid: Description and Operation TORQUE CONVERTOR CLUTCH (TCC) SOLENOID-PCM OUTPUT This circuit controls operation of the transmission mounted torque convertor clutch (TCC) solenoid used for torque convertor engagement. The powertrain control module (PCM) will determine when to engage and disengage the solenoid by monitoring vehicle miles per hour (mph) versus the output voltage of the throttle position sensor. Also needed are various inputs from: Transmission temperature sensor - Output shaft speed sensor - Module timer - Engine rpm - MAP sensor - Brake switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair Accumulator: Service and Repair For Accumulator Cleaning and Inspection procedures, Refer to Automatic Transmission/Transaxle, Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > A/T - (42RE) Revised Front Band Adjustment Band: Technical Service Bulletins A/T - (42RE) Revised Front Band Adjustment NO: 21-16-98 GROUP: Transmission DATE: Dec. 4, 1998 SUBJECT: Revised Front Band Adjustment For 42RE Transmissions MODELS: 1999 (AN) Dakota 1999 (BR) Ram Truck 1999 (DN) Durango 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 42RE TRANSMISSION. DISCUSSION: The final adjustment for the front band has been changed to 3 turns. Whenever performing this adjustment on a 1999 model 42RE transmission, be sure to only back off the adjusting screw 3 turns prior to torquing the lock nut. All other steps of the procedure are unchanged. Service manual revision pages will be sent at a later date to address this change. POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > Page 3239 Band: Specifications Band Adjuster Locknut Front 25 ft.lb Rear 30 ft.lb Band adjustment from 72 inch lbs. Front band Back off 2-7/8 turns Rear band Back off 4 turns Plug, front band reaction 13 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Adjustments > Front Band Adjustment Band: Adjustments Front Band Adjustment The front (kickdown) band adjusting screw is located on the left side of the transmission case above the manual valve and throttle valve levers. 1. Raise vehicle. Fig. 257 2. Loosen band adjusting screw locknut (Fig. 257). Then back locknut off 3-5 turns. Be sure adjusting screw turns freely in case. Apply lubricant to screw threads if necessary. 3. Tighten band adjusting screw to 8 Nm (72 inch lbs.) torque with Inch Pound Torque Wrench C-3380-A, a 3-inch extension and 5/16 socket. Fig. 258 CAUTION: If Adapter C-3705 is needed to reach the adjusting screw (Fig. 258), tighten the screw to only 5 Nm (47-50 inch lbs.) torque. 4. Back off front band adjusting screw 2-7/8 turns. 5. Hold adjuster screw in position and tighten locknut to 41 Nm (30 ft. lbs.) torque. 6. Lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Adjustments > Front Band Adjustment > Page 3242 Band: Adjustments Rear Band Adjustment The transmission oil pan must be removed for access to the rear band adjusting screw. 1. Raise vehicle. 2. Remove transmission oil pan and drain fluid. 3. Loosen band adjusting screw locknut 5-6 turns. Be sure adjusting screw turns freely in lever. Fig. 259 4. Tighten adjusting screw to 8 Nm (72 inch lbs.) torque (Fig. 259). 5. Back off adjusting screw 2 turns. 6. Hold adjusting screw in place and tighten locknut to 34 Nm (25 ft. lbs.) torque. 7. Position new gasket on oil pan and install pan on transmission. Tighten pan bolts to 17 Nm (13 ft. lbs.) torque. 8. Lower vehicle and refill transmission with MOPAR ATF+4, Type 9602 fluid. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Specifications Band Apply Servo: Specifications PRESSURE SPECIFICATIONS Front Servo (3rd Gear Only) Not less than line pressure by ............................................................................................................. ................................................................... 3 psi Rear Servo 1 Range Not less than line pressure by ............................................................................................................. ............................................................. 3 psi R Range At Idle .................................................................................................................................................. ........................................................ 160 psi At 1600 rpm ................................................................... .............................................................................................................................. 270 psi Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Cleaning and Inspection Band Apply Servo: Service and Repair Cleaning and Inspection For front or rear Band Apply Servo Cleaning and Inspection Procedures, Refer to Automatic Transmission/Transaxle, Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Cleaning and Inspection > Page 3248 Band Apply Servo: Service and Repair Disassembly and Assembly For front or rear Band Apply Servo component service, refer to Automatic Transmission/Transaxle, Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Mechanical Specifications Clutch: Mechanical Specifications Disc Usage 8 discs ct Clutch pack clearance Clutch pack clearance Clutch pack clearance/ Front 3-disc. 0.070-0.129 in Front clutch spring usage 9 springs Front clutch thrust washer (reaction shaft support hub) 0.061 inch 0.084 inch 0.102 inch One-Way Clutch TIGHTENING SPECIFICATIONS Bolt, overrunning clutch cam ............................................................................................................... ............................................................... 13 ft. lbs. Overdrive clutch disc usage 4 discs ct Clutch pack clearance/ Rear 4-disc. 0.025-0.045 in Rear clutch thrust washer (clutch retainer) 0.061 inch Rear clutch pack snap ring 0.060-0.062 inch 0.074-0.076 inch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Mechanical Specifications > Page 3253 Clutch: Pressure, Vacuum and Temperature Specifications PRESSURE SPECIFICATIONS Overdrive Clutch (4th Gear Only) Closed Throttles .................................................................................................................................. .......................................................... 68-72 psi 1/2 to 3/4 Throttles .................................................... .................................................................................................................................. 90-130 psi Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Cleaning and Inspection Clutch: Service and Repair Cleaning and Inspection Front Clutch For Front Clutch Cleaning and Inspection Procedures, Refer to Automatic Transmission/Transaxle, Service and Repair. One-Way Clutch For Overrunning Clutch/Low-Reverse Drum/Overdrive Piston Retainer Cleaning and Inspection Procedures, Refer to Automatic Transmission/Transaxle , Service and Repair. Rear Clutch For Rear Clutch Cleaning and Inspection Procedures, Refer to Automatic Transmission/Transaxle, Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Cleaning and Inspection > Page 3256 Clutch: Service and Repair Disassembly and Assembly Front Clutch For Front Clutch component service, refer to Automatic Transmission/Transaxle, Service and Repair. One-Way Clutch For Overrunning Clutch/Low-Reverse Drum/Overdrive Piston Retainer component service, refer to Automatic Transmission/Transaxle, Service and Repair. Rear Clutch For Rear Clutch component service, refer to Automatic Transmission/Transaxle, Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3265 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3266 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3272 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3273 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3274 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair Extension Housing: Service and Repair Refer to Overdrive Unit, A/T Service and Repair for procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3282 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3283 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3284 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3285 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3286 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Total Capacity ...................................................................................................................................... .............................................. 9.1-9.5L (9.6-10.0 Qt) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 3289 Fluid - A/T: Fluid Type Specifications See TSB 21-010-06 4/14/2006 Mopar (R) ATF Plus 4, Type 9602 automatic transmission fluid is the recommended fluid type. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 3290 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 OVERVIEW Transmission fluid level should be checked monthly under normal operation. If the vehicle is used for trailer towing or similar heavy load hauling, check fluid level and condition weekly. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. FLUID LEVEL CHECK PROCEDURE 1. Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82°C (180°F). 2. Position vehicle on level surface. 3. Start and run engine at curb idle speed. 4. Apply parking brakes. 5. Shift transmission momentarily into all gear ranges. Then shift transmission back to Neutral. 6. Clean top of filler tube and dipstick to keep dirt from entering tube. Fig. 10 7. Remove dipstick (Fig. 10) and check fluid level as follows: a. Correct acceptable level is in crosshatch area. b. Correct maximum level is to MAX arrow mark. c. Incorrect level is at or below MIN line. d. If fluid is low, add only enough MOPAR ATF+4 to restore correct level. Do not overfill. CAUTION: Do not overfill the transmission. Overfilling may cause leakage out the pump vent which can be mistaken for a pump seal leak. Overfilling will also cause fluid aeration and foaming as the excess fluid is picked up and churned by the gear train. This will significantly reduce fluid life. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 3293 Fluid - A/T: Service and Repair Fluid and Filter Replacement Refer to the Maintenance Schedules in Maintenance, for proper service intervals. The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. Fig. 11 3. Remove bolts holding front and sides of pan to transmission (Fig. 11). 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 bolt holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. Fig. 12 9. Remove screws holding filter to valve body (Fig. 12). 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used bans fluid and filter properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal or fiber contamination. A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompanied by slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts or debris, refer to Diagnosis and Testing. Check the adjustment of the front and rear bands, adjust if necessary. CLEANING Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 3294 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean gasket material from gasket surface of transmission case and the gasket flange around the pan. INSTALLATION 1. Place replacement filter in position on valve body. 2. Install screws to hold filter to valve body (Fig. 12). Tighten screws to 4 Nm (35 inch lbs.) torque. 3. Place new gasket in position on pan and install pan on transmission. 4. Place pan in position on transmission. 5. Install screws to hold pan to transmission (Fig. 11). Tighten bolts to 17 Nm (150 inch lbs.) torque. 6. Lower vehicle and fill transmission with MOPAR ATF+4, type 9602 fluid. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Specifications Fluid Filter - A/T: Specifications Screws, fluid filter 35 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications TORQUE SPECIFICATIONS 42/44RE, 46RE Bolt, Fluid Pan ........................................................................................................... ............................................................................... 17 Nm (13 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications Fluid Pump: Specifications Oil pump gear tip clearance 0.004-0.008 in Bolt, oil pump 15 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Service Procedures Fluid Pump: Service and Repair Service Procedures After the new or repaired transmission has been installed, fill to the proper level with MOPAR(r) ATF+4 (Type 9602) automatic transmission fluid. The volume should be checked using the following procedure: 1. Disconnect the From cooler line at the transmission 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 curb idle speed, with the shift selector in neutral. 3. If fluid flow is intermittent or it takes more than 20 seconds to collect one quart of ATF+4, disconnect the To Cooler line at the transaxle. 4. Refill the transaxle to proper level and recheck pump volume. 5. If flow is found to be within acceptable limits, replace the cooler. Then fill transmission to the proper level, using MOPAR ATF+4 (Type 9602) automatic transmission fluid. 6. If fluid flow is still found to be inadequate, check the line pressure using the Transaxle Hydraulic Pressure Test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Service Procedures > Page 3306 Fluid Pump: Service and Repair Disassembly and Assembly For Oil Pump component service, refer to Automatic Transmission/Transaxle, Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Service Procedures > Page 3307 Fluid Pump: Service and Repair Cleaning and Inspection For Oil Pump and Reaction Shaft Support Cleaning and Inspection Procedures, Refer to Automatic Transmission/Transaxle, Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Specifications Governor: Specifications PRESSURE SPECIFICATIONS D Range (Closed Throttle) At Idle In D, 1 or 2 ................................................................................................................................ .......................................................... 0-1.5 psi NOTE: - Pressure should respond smoothly to changes in mph and return to 0-1.5 psi. - Pressure at stand still above 1.5 psi will prevent transmission from downshifting. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Specifications > Page 3311 Governor: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Specifications > Page 3312 Governor Pressure Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Description and Operation > Electronic Governor Governor: Description and Operation Electronic Governor OVERVIEW 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 Fig. 3 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. 3). 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 bans 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 Fig. 4 The governor pressure sensor measures output pressure of the governor pressure solenoid valve (Fig. 4). The sensor output signal provides the necessary feedback to the PCM. This feedback is needed to adequately control governor pressure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Description and Operation > Electronic Governor > Page 3315 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. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Description and Operation > Electronic Governor > Page 3316 Governor: Description and Operation 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, 100°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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Replacement Governor: Service and Repair Replacement REMOVAL 1. Hoist and support vehicle on safety stands. 2. Remove transmission fluid pan and filter. 3. Disengage wire connectors from pressure sensor and solenoid. 4. Remove screws holding pressure solenoid retainer to governor body. 5. Separate solenoid retainer from governor. 6. Pull solenoid from governor body. 7. Remove bolts holding governor body to valve body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Replacement > Page 3319 8. Separate governor body from valve body. 9. Remove governor body gasket. 10. Remove retainer holding pressure sensor to governor body. 11. Pull pressure sensor from governor body. NOTE: Before installing the pressure sensor and solenoid in the governor body, replace O-ring seals, clean the gasket surfaces and replace gasket. INSTALLATION 1. Lubricate O-ring on pressure sensor with transmission fluid. 2. Align pressure sensor to bore in governor body. 3. Push pressure sensor into governor body. 4. Install retainer to hold pressure sensor to governor body. 5. Place gasket in position on back of governor body. 6. Place governor body in position on valve body. 7. Install bolts to hold governor body to valve body. 8. Lubricate O-ring, on pressure solenoid, with transmission fluid. 9. Align pressure solenoid to bore in governor body. 10. Push solenoid into governor body. 11. Place solenoid retainer in position on governor. 12. Install screws to hold pressure solenoid retainer to governor body. 13. Engage wire connectors into pressure sensor and solenoid. 14. Install transmission fluid pan and (new) filter. 15. Lower vehicle and road test to verify repair. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Replacement > Page 3320 Governor: Service and Repair Removal and Installation REMOVAL 1. Hoist and support vehicle on safety stands. 2. Remove transmission fluid pan and filter. Fig. 22 3. Disengage wire connectors from pressure sensor and solenoid (Fig. 22). 4. Remove screws holding pressure solenoid retainer to governor body. Fig. 23 5. Separate solenoid retainer from governor (Fig. 23). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Replacement > Page 3321 Fig. 24 6. Pull solenoid from governor body (Fig. 24). 7. Remove bolts holding governor body to valve body. Fig. 25 8. Separate governor body from valve body (Fig. 25). 9. Remove governor body gasket. 10. Remove retainer holding pressure sensor to governor body. Fig. 26 11. Pull pressure sensor from governor body (Fig. 26). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Replacement > Page 3322 INSTALLATION Before installing the pressure sensor and solenoid in the governor body, replace O-ring seals, clean the gasket surfaces and replace gasket. 1. Lubricate O-ring on pressure sensor with transmission fluid. 2. Align pressure sensor to bore in governor body. 3. Push pressure sensor into governor body. 4. Install retainer to hold pressure sensor to governor body. 5. Place gasket in position on back of governor body. 6. Place governor body in position on valve body. 7. Install bolts to hold governor body to valve body. 8. Lubricate O-ring, on pressure solenoid, with transmission fluid. 9. Align pressure solenoid to bore in governor body. 10. Push solenoid into governor body. 11. Place solenoid retainer in position on governor. 12. Install screws to hold pressure solenoid retainer to governor body. 13. Engage wire connectors into pressure sensor and solenoid. 14. Install transmission fluid pan and (new) filter. 15. Lower vehicle and road test to verify repair. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Intermediate Shaft, A/T > Component Information > Specifications Intermediate Shaft: Specifications THICKNESS SPECIFICATION Intermediate Shaft Thrust Plate (Shaft Hub Pilot) ................................................................................................................................... 0.060-0.063 inch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation OVERDRIVE LAMP-PCM OUTPUT This circuit controls a signal for the operation of the push-button overdrive lamp switch. When the lamp is illuminated, the overdrive is disengaged. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Service and Repair > Page 3336 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications Output Shaft: Specifications OVERVIEW Output shaft thrust plate (output shaft pilot hub) ..................................................................................................................................... 0.060-0.063 inch Output shaft thrust washer (rear clutch hub) .............................................................................................................................................................. ............................................ 0.052-0.054 inch ..................................................................................... ..................................................................................................................... 0.068-0.070 inch ............ .............................................................................................................................................................. ................................ 0.083-0.085 inch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Service and Repair > Rear Bearing Output Shaft: Service and Repair Rear Bearing REMOVAL 1. Remove overdrive unit from the vehicle. 2. Remove overdrive geartrain from housing. Fig. 37 3. Remove snap ring holding output shaft rear bearing into overdrive housing (Fig. 37). 4. Using a suitable driver inserted through the rear end of housing, drive bearing from housing. INSTALLATION 1. Place replacement bearing in position in housing. 2. Using a suitable driver, drive bearing into housing until the snap ring groove is visible. 3. Install snap ring to hold bearing into housing. 4. Install overdrive geartrain into housing. 5. Install overdrive unit in vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Service and Repair > Rear Bearing > Page 3342 Output Shaft: Service and Repair Front Bearing REMOVAL 1. Remove overdrive unit from the vehicle. 2. Remove overdrive geartrain from housing. Fig. 38 3. Remove snap ring holding output shaft front bearing to overdrive geartrain (Fig. 38). 4. Pull bearing from output shaft. INSTALLATION 1. Place replacement bearing in position on geartrain with locating retainer groove toward the rear. 2. Push bearing onto shaft until the snap ring groove is visible. 3. Install snap ring to hold bearing onto output shaft. 4. Install overdrive geartrain into housing. 5. Install overdrive unit in vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Specifications > Tightening Overdrive Assembly: Specifications Bolt, O/D to trans 25 ft.lb Bolt, O/D piston retainer 13 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Specifications > Tightening > Page 3347 Overdrive Assembly: Specifications Thrust Plate and Spacer Dimensions THICKNESS SPECIFICATIONS Overdrive piston thrust plate ................................................................................................................ ................................................................ See Note Intermediate shaft spacer ................................... .................................................................................................................................................. See Note NOTE: Thrust plate and spacer are select fit. Refer to size charts and selection procedures in Overdrive Unit D & A procedures Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Specifications > Page 3348 Overdrive Assembly: Description and Operation The overdrive clutch is applied in fourth gear only. The direct clutch is applied in all ranges except fourth gear. Fourth gear overdrive range is electronically controlled and hydraulically activated. Various sensor inputs are supplied to the powertrain control module to operate the overdrive solenoid on the valve body. The solenoid contains a check ball that opens and closes a vent port in the 3-4 shift valve feed passage. The overdrive solenoid (and check ball) are not energized in first, second, third, or reverse gear. The vent port remains open, diverting line pressure from the 2-3 shift valve away from the 3-4 shift valve. The overdrive control switch must be in the ON position to transmit overdrive status to the PCM. A 3-4 upshift occurs only when the overdrive solenoid is energized by the PCM. The PCM energizes the overdrive solenoid during the 3-4 upshift. This causes the solenoid check ball to close the vent port allowing line pressure from the 2-3 shift valve to act directly on the 3-4 upshift valve. Line pressure on the 3-4 shift valve overcomes valve spring pressure moving the valve to the upshift position. This action exposes the feed passages to the 3-4 timing valve, 3-4 quick fill valve, 3-4 accumulator, and ultimately to the overdrive piston. Line pressure through the timing valve moves the overdrive piston into contact with the overdrive clutch. The direct clutch is disengaged before the overdrive clutch is engaged. The boost valve provides increased fluid apply pressure to the overdrive clutch during 3-4 upshifts, and when accelerating in fourth gear. The 3-4 accumulator cushions overdrive clutch engagement to smooth 3-4 upshifts. The accumulator is charged at the same time as apply pressure acts against the overdrive piston. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Removal and Installation Overdrive Assembly: Service and Repair Removal and Installation Overdrive Unit REMOVAL 1. Shift transmission into Park. 2. Raise vehicle. 3. Mark propeller shaft universal joint(s) and axle pinion yoke for alignment reference at installation. 4. Disconnect and remove propeller shaft(s). 5. Remove transmission oil pan, remove gasket, drain oil and reinstall pan. 6. If overdrive unit had malfunctioned, or if fluid is contaminated, remove entire transmission. If diagnosis indicated overdrive problems only, remove just the overdrive unit. 7. Support transmission with transmission jack. Fig. 32 8. Remove bolts attaching overdrive unit to transmission (Fig. 32) CAUTION: Support the overdrive unit with a jack before moving it rearward. This is necessary to prevent damaging the intermediate shaft. Do not allow the shaft to support the entire weight of the overdrive unit. 9. Carefully work overdrive unit off intermediate shaft. Do not tilt unit during removal. Keep it as level as possible. 10. If overdrive unit does not require service, immediately insert Alignment Tool 6227-2 in splines of planetary gear and overrunning clutch to prevent splines from rotating out of alignment. If misalignment occurs, overdrive unit will have to be disassembled in order to realign splines. 11. Remove and retain overdrive piston thrust bearing. Bearing may remain on piston or in clutch hub during removal. 12. Position drain pan on workbench. 13. Place overdrive unit over drain pan. Tilt unit to drain residual fluid from case. 14. Examine fluid for clutch material or metal fragments. If fluid contains these items, overhaul will be necessary. 15. If overdrive unit does not require any service, leave alignment tool in position. Tool will prevent accidental misalignment of planetary gear and overrunning clutch splines. INSTALLATION 1. Be sure overdrive unit Alignment Tool 6227-2 is fully seated before moving unit. If tool is not seated and gear splines rotate out of alignment, overdrive unit will have to be disassembled in order to realign splines. 2. If overdrive piston retainer was not removed during service and original case gasket is no longer reusable, prepare new gasket by trimming it. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Removal and Installation > Page 3351 Fig. 33 3. Cut out old case gasket around piston retainer with razor knife (Fig. 33). 4. Use old gasket as template and trim new gasket to fit. 5. Position new gasket over piston retainer and on transmission case. Use petroleum jelly to hold gasket in place if necessary. Do not use any type of sealer to secure gasket. Use petroleum jelly only. Fig. 34 6. Install selective spacer on intermediate shaft, if removed. Spacer goes in groove just rearward of shaft rear splines (Fig. 34). 7. Install thrust bearing in overdrive unit sliding hub. Use petroleum jelly to hold bearing in position. CAUTION: Be sure the shoulder on the inside diameter of the bearing is facing forward. 8. Verify that splines in overdrive planetary gear and overrunning clutch hub are aligned with Alignment Tool 6227-2. Overdrive unit cannot be installed if splines are not aligned. If splines have rotated out of alignment, unit will have to be disassembled to realign splines. 9. Carefully slide Alignment Tool 6227-2 out of overdrive planetary gear and overrunning clutch splines. 10. Raise overdrive unit and carefully slide it straight onto intermediate shaft. Insert park rod into park lock reaction plug at same time. Avoid tilting overdrive during installation as this could cause planetary gear and overrunning clutch splines to rotate out of alignment. If this occurs, it will be necessary to remove and disassemble overdrive unit to realign splines. 11. Work overdrive unit forward on intermediate shaft until seated against transmission case. 12. Install bolts attaching overdrive unit to transmission unit. Tighten bolts in diagonal pattern to 34 Nm (25 ft. lbs.). 13. Align and install propeller shaft(s). Overdrive Housing Bushing REMOVAL 1. Remove overdrive housing yoke seal. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Removal and Installation > Page 3352 Fig. 35 2. Insert Remover 6957 into overdrive housing. Tighten tool to bushing and remove bushing (Fig. 35). INSTALLATION 1. Align bushing oil hole with oil slot in overdrive housing. 2. Tap bushing into place with Installer 6951 and Handle C-4171. Fig. 36 3. Install new oil seal in housing using Seal Installer C-3995-A (Fig. 36). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Removal and Installation > Page 3353 Overdrive Assembly: Service and Repair Disassembly and Assembly For Overdrive Unit component service, refer to Automatic Transmission/Transaxle, Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Removal and Installation > Page 3354 Overdrive Assembly: Service and Repair Cleaning and Inspection For Overdrive Unit Cleaning and Inspection Procedures, Refer to Automatic Transmission/Transaxle, Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation OVERDRIVE LAMP-PCM OUTPUT This circuit controls a signal for the operation of the push-button overdrive lamp switch. When the lamp is illuminated, the overdrive is disengaged. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations Overdrive Cancel Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 3361 Automatic Transmission Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 3362 Overdrive Switch: Description and Operation OVERDRIVE/OVERRIDE SWITCH-PCM INPUT On vehicles equipped with an automatic transmission and overdrive, the powertrain control module (PCM) regulates the 3-4 overdrive up-shift and downshift through the overdrive solenoid. This solenoid is located in the transmission. An overdrive/override push-button switch is located at the end of transmission shift lever. The overdrive/override push-button switch is normally open (overdrive allowed) when the lamp is not illuminated. It momentarily closes (overdrive not allowed) when the operator presses the switch and the lamp is illuminated. Overdrive will revert to ON (lamp off) each time the ignition switch in turned on. The transmission downshifts if the operator presses the override switch while in overdrive. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Specifications > Dimensional Planetary Gears: Specifications Dimensional END PLAY SPECIFICATIONS Planetary end play ............................................................................................................................... .................................................... 0.006-0.048 inch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Specifications > Dimensional > Page 3367 Planetary Gears: Specifications Snap Ring Thickness THICKNESS SPECIFICATIONS Planetary geartrain snap ring (at front of output shaft) .............................................................................................................................................................. ............................................ 0.055-0.059 inch ..................................................................................... ..................................................................................................................... 0.062-0.066 inch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair > Disassembly and Assembly Planetary Gears: Service and Repair Disassembly and Assembly For Planetary Geartrain component service, refer to Automatic Transmission/Transaxle, Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3370 Planetary Gears: Service and Repair Cleaning and Inspection For Planetary Geartrain Cleaning and Inspection Procedures, Refer to Automatic Transmission/Transaxle, Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: Customer Interest A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3379 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3385 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3395 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3396 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3402 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3403 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3404 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 The Transmission Relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3408 Transmission Control System Relay: Diagrams Transmission Control Relay Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3409 Transmission Control & Wiper Relays And C106 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3410 Transmission Control System Relay: Description and Operation TRANSMISSION RELAY-PCM OUTPUT The output to this relay provides battery voltage to the overdrive (OD), torque converter clutch (TCC) and governor pressure solenoids. Once battery voltage is applied to the solenoids, they are individually activated by the PCM through OD, TCC and governor pressure outputs. The relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair Seals and Gaskets: Service and Repair REMOVAL 1. Raise vehicle. 2. Mark propeller shaft and axle yoke for alignment reference. 3. Disconnect and remove propeller shaft. Fig. 17 4. Remove old seal with Seal Remover C-3985-B (Fig. 17) from overdrive housing. INSTALLATION 1. Place seal in position on overdrive housing. Fig. 18 2. Drive seal into overdrive housing with Seal Installer C-3995-A (Fig. 18). 3. Carefully guide propeller shaft slip yoke into housing and onto output shaft splines. Align marks made at removal and connect propeller shaft to rear axle pinion yoke. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations Overdrive Cancel Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3418 Automatic Transmission Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3419 Overdrive Switch: Description and Operation OVERDRIVE/OVERRIDE SWITCH-PCM INPUT On vehicles equipped with an automatic transmission and overdrive, the powertrain control module (PCM) regulates the 3-4 overdrive up-shift and downshift through the overdrive solenoid. This solenoid is located in the transmission. An overdrive/override push-button switch is located at the end of transmission shift lever. The overdrive/override push-button switch is normally open (overdrive allowed) when the lamp is not illuminated. It momentarily closes (overdrive not allowed) when the operator presses the switch and the lamp is illuminated. Overdrive will revert to ON (lamp off) each time the ignition switch in turned on. The transmission downshifts if the operator presses the override switch while in overdrive. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3423 Transmission Position Switch/Sensor: Description and Operation TRANSMISSION PARK/NEUTRAL SWITCH-PCM INPUT The park/neutral switch is located on the transmission housing and provides an input to the Powertrain Control Module (PCM), This will indicate that the automatic transmission is in Park, Neutral or a drive gear selection. This input is used to determine idle speed (varying with gear selection), fuel injector pulse width, ignition timing advance and vehicle speed control operation. The center terminal of the park/neutral position switch is the starter-circuit terminal. It provides the ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. The outer terminals on the switch are for the backup lamp circuit. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3424 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Sensor Mounting ................................................................................................................................. ..................................................... 27 Nm (20 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 3428 Output Shaft Speed Sensor, Park/Neutral Switch, Transmission Solenoid 8-Way Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 3429 Output Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input Transmission Speed Sensor: Description and Operation Output Shaft Speed Sensor-PCM Input This sensor generates a signal to the PCM relating to the speed of the transmission main drive shaft. NOTE: This input is used with 4-speed electronic transmissions only. CIRCUIT OPERATION Four Speed Automatic Transmission The output shaft speed sensor generates a signal indicating the speed of the transmission output shaft. Circuits T13 and T14 connect the sensor to the Powertrain Control Module (PCM). Circuit T13 connects to cavity B25 of the PCM. Circuit T14 connects to cavity B28. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input > Page 3432 Transmission Speed Sensor: Description and Operation Sensor Operation The speed sensor is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. The vehicle speed sensor also serves as a backup for the transmission speed sensor. Signals from this sensor are shared with the powertrain control module. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 3433 Transmission Speed Sensor: Service and Repair Removal Transmission Speed Sensor Removal Installation 1. Remove transmission speed sensor and O-ring seal from overdrive case. Installation 1. Install transmission speed sensor and O-ring seal in overdrive case. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 3437 Transmission Temperature Sensor/Switch: Description and Operation TRANSMISSION TEMPERATURE SENSOR-PCM INPUT This input is used in the shift operation for 4-speed electronic transmissions only. The temperature data is used for: torque converter clutch operation, overdrive shift, low temperature shift compensation, wide open throttle shift strategy and governor pressure transducer calibration. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Service and Repair Shift Interlock: Service and Repair The column shift interlock is used to lock the transmission shifter in the Park position when the key is in the Off position. The interlock device is located within the steering column assembly and is not serviceable. If repair is necessary, the steering column assembly must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Component Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Component Locations > Page 3445 Output Shaft Speed Sensor, Park/Neutral Switch, Transmission Solenoid 8-Way Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 3446 Automatic Transmission Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 3447 Shift Solenoid: Description and Operation THREE-FOUR SHIFT SOLENOID-PCM OUTPUT This output is used to control the transmission three-four shift solenoid. It is used on 4-speed electronically controlled automatic transmissions only. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair Shifter A/T: Service and Repair REMOVAL Gear Shift Lever 1. Support the steering column assembly as shown, using a suitable size socket. 2. Disconnect over drive switch wiring. 3. Using a drift of the appropriate size drive the pin out of the steering column and gear shift lever. Remove the gear shift lever from the steering column assembly. INSTALLATION 1. Support the steering column using a suitable size socket. 2. Install the gear shift lever into the steering column assembly. Align the pin holes in the gear shift lever and the steering column assembly. 3. Carefully Install the pin into the steering column assembly and through the shift lever. If the pin binds check the alignment on the holes. Be sure pin is fully installed into the steering column assembly. 4. Connect over drive switch wiring. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments Shift Cable: Adjustments Check adjustment by starting the engine in Park and Neutral. Adjustment is OK 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 park/neutral position switch may be faulty. Gearshift Adjustment Procedure 1. Shift transmission into Park. Fig. 256 2. Release cable adjuster lock (underneath the power brake booster) (Fig. 256) to unlock cable. 3. Raise vehicle. 4. Slide cable eyelet off transmission 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. Slide cable eyelet onto transmission shift lever. 8. Lower vehicle and check engine starting. Engine should start only in Park and Neutral. 9. Lock shift cable by pressing cable adjuster solemn down into place. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 3455 Shift Cable: Service and Repair REMOVAL 1. Shift transmission into Park. Fig. 20 2. Remove nuts retaining the shift cable housing to the dash panel (Fig. 20). Fig. 21 3. Disconnect cable at lower column lever and feed cable through dash panel opening to underside of vehicle (Fig. 21). 4. Raise vehicle. 5. Disengage cable eyelet at transmission shift lever and pull cable adjuster out of mounting INSTALLATION 1. Snap the cable into the transmission bracket so the retaining ears are engaged and connect cable end fitting onto the manual control lever ball stud. 2. Lower vehicle. 3. Route cable through hole in dash panel. Seat cable bracket to dash panel. Install retaining nuts to cable housing bracket studs inside the vehicle at the dash panel. 4. Place the auto transmission manual shift control lever in "Park" detent (rearmost) position and rotate prop shaft to ensure transmission is in park. 5. Connect shift cable to shifter lever by snapping cable retaining ears into shifter bracket and press cable end fitting into lever. 6. Check for proper operation of Park/Neutral switch. 7. If the gearshift cable is out of adjustment, refer to Adjustment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments Throttle Valve Cable/Linkage: Adjustments OVERVIEW Fig. 255 The transmission throttle valve is operated by a cam on the valve body throttle lever. The throttle lever is actuated by a cable connected to the engine throttle body lever (Fig. 255). 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. 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 allows simultaneous movement without causing the transmission throttle lever to move ahead of, or lag behind the throttle body lever. THROTTLE VALVE CABLE ADJUSTMENT CHECK 1. Turn ignition key to OFF position. 2. Remove air cleaner. 3. Slide cable off attachment stud on throttle body lever. 4. Verify that throttle body lever is at curb idle position. Then verify that transmission throttle lever is also at idle (full forward) position. 5. Compare position of cable end to attachment stud on throttle body lever: a. Cable end and attachment stud should be aligned (or centered on one another) to within 1 mm (0.039 inch) in either direction. b. If cable end and attachment stud are misaligned (off center), cable will have to be adjusted as described in following procedure. 6. Reconnect cable end to attachment stud. Then with aid of a helper, observe movement of transmission throttle lever and lever on throttle body. a. If both levers move simultaneously from idle to half-throttle and back to idle position, adjustment is correct. b. If transmission throttle lever moves ahead of, or lags behind throttle body lever, cable adjustment will be necessary. Or, if throttle body lever prevents transmission lever from returning to closed position, cable adjustment will be necessary. THROTTLE VALVE CABLE ADJUSTMENT PROCEDURE 1. Turn ignition switch to OFF position and shift into Park. 2. Remove air cleaner. 3. Disconnect cable end from attachment stud on throttle body. Carefully slide cable off stud. Do not pull or pry cable off. 4. Verify that transmission throttle lever is in idle (full forward) position. Then be sure lever on throttle body is at curb idle position. 5. Insert a small screwdriver under edge of retaining clip and remove retaining clip. 6. Center cable end on attachment stud to within 1 mm (0.039 inch). 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. 7. Install retaining clip onto cable housing. 8. Check cable adjustment. Be sure transmission throttle lever and lever on throttle body move simultaneously and as described in cable adjustment checking procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications Torque Converter: Specifications Torque Convertor Drive Plate Bolts 270 in.lb Bolt, torque convertor 23 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 3462 Torque Converter: Service and Repair 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 converter hub and 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. Fig. 16 6. Check converter seating with a scale and straightedge (Fig. 16). Surface of converter lugs should be 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Description and Operation Torque Converter Check Valve: Description and Operation The drainback valve is located in the transmission cooler outlet (pressure) line. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Description and Operation > Page 3466 Torque Converter Check Valve: Service and Repair The converter drainback check valve is located in the cooler outlet (pressure) line near the radiator tank. The valve prevents fluid drainback when the vehicle is parked for lengthy periods. The valve check ball is spring loaded and has an opening pressure of approximately 2 psi. The valve is serviced as an assembly; it is not repairable. Do not clean the valve if restricted, or contaminated by sludge, or debris. If the valve fails, or if a transmission malfunction occurs that generates significant amounts of sludge and/or clutch particles and metal shavings, the valve must be replaced. The valve must be removed whenever the cooler and lines are reverse flushed. The valve can be flow tested when necessary. The procedure is exactly the same as for flow testing a cooler. If the valve is restricted, installed backwards, or in the wrong line, it will cause an overheating condition and possible transmission failure. CAUTION: The drainback valve is a one-way flow device. It must be properly oriented in terms of flow direction for the cooler to function properly. The valve must be installed in the pressure line. Otherwise flow will be blocked and would cause an overheating condition and eventual transmission failure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Description and Operation > Converter Clutch Engagement Torque Converter Clutch: Description and Operation Converter Clutch Engagement Converter clutch engagement in third or fourth gear range is controlled by sensor inputs to the powertrain control module. Inputs that determine clutch engagement are: coolant temperature, engine rpm, vehicle speed, throttle position, and manifold vacuum. The torque converter clutch is engaged by the clutch solenoid on the valve body. The clutch can be engaged in 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Description and Operation > Converter Clutch Engagement > Page 3471 Torque Converter Clutch: Description and Operation Quick Fill Valve The 3-4 quick fill valve provides faster engagement of the overdrive clutch during 3-4 upshifts. The valve temporarily bypasses the clutch piston feed orifice at the start of a 3-4 upshift. This exposes a larger passage into the piston retainer resulting in a much faster clutch fill and apply sequence. The quick fill valve does not bypass the regular clutch feed orifice throughout the 3-4 upshift. Instead, once a predetermined pressure develops within the clutch, the valve closes the bypass. Clutch fill is then completed through the regular feed orifice. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3475 Automatic Transmission Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3476 Torque Converter Clutch Solenoid: Description and Operation TORQUE CONVERTOR CLUTCH (TCC) SOLENOID-PCM OUTPUT This circuit controls operation of the transmission mounted torque convertor clutch (TCC) solenoid used for torque convertor engagement. The powertrain control module (PCM) will determine when to engage and disengage the solenoid by monitoring vehicle miles per hour (mph) versus the output voltage of the throttle position sensor. Also needed are various inputs from: Transmission temperature sensor - Output shaft speed sensor - Module timer - Engine rpm - MAP sensor - Brake switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 The Transmission Relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3480 Transmission Control System Relay: Diagrams Transmission Control Relay Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3481 Transmission Control & Wiper Relays And C106 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3482 Transmission Control System Relay: Description and Operation TRANSMISSION RELAY-PCM OUTPUT The output to this relay provides battery voltage to the overdrive (OD), torque converter clutch (TCC) and governor pressure solenoids. Once battery voltage is applied to the solenoids, they are individually activated by the PCM through OD, TCC and governor pressure outputs. The relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications Transmission Cooler: Specifications Transmission Auxiliary Oil Cooler Bolts 90 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 3486 Transmission Cooler: Description and Operation Oil Flow To Cooler-Top View (Typical) The automatic transmission oil is cooled when it passes through a cooler in radiator outlet tank. This cooler is only to be serviced by radiator replacement. CAUTION: 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. AUXILIARY OIL-TO-AIR COOLER Transmission Oil Auxiliary Cooler Typical Oil-to-air (auxiliary) transmission coolers are mounted ahead of radiator. They operate in conjunction with main cooler located in radiator side tank. The transmission oil is routed through main cooler in radiator side tank first. It is then routed through auxiliary cooler before returning to transmission. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 3487 Transmission Cooler: Service and Repair 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 Cooler Flusher. WARNING: WEAR PROTECTIVE EYEWEAR 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. COOLER FLUSH USING TOOL 6906 1. Remove cover plate filler plug on Tool 6906. 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. 3. Verify pump power switch is turned OFF. Connect red alligator clip to positive (+) battery post. Connect black (-) 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. 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. Monitor pressure readings and clear return lines. Pressure readings should stabilize below 20 psi. for vehicles equipped with a single cooler and 30 psi. for vehicles equipped with dual coolers. If flow is intermittent or exceeds these pressures, replace cooler. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications Transmission Mount: Specifications Rear Insulator-to-Crossmember Nuts 50 ft.lb Rear Insulator-to-Transmission Bolts 50 ft.lb Rear Insulator Bracket Bolts 50 ft.lb Rear Support Bracket-to-Crossmember Flange 30 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Page 3491 Transmission Mount: Service and Repair ENGINE MOUNT-REAR REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise the vehicle on a hoist. 3. Support the transmission with a transmission jack. Rear Mount Insulator 4. Remove stud nuts holding the insulator to the crossmember. 5. Raise rear of transmission SLIGHTLY. 6. Remove bolts holding the insulator to the insulator bracket. Remove the insulator. INSTALLATION 1. If the insulator bracket was removed, install the bracket to the transmission. Tighten the bolts to 28 Nm (250 inch lbs.) torque. 2. Install the bolts holding insulator to insulator bracket. Tighten the bolts to 28 Nm (250 inch lbs.) torque. 3. Lower rear of transmission while aligning the insulator studs into the mounting support bracket. Install stud nuts and tighten to 28 Nm (250 inch lbs.) torque. 4. Remove the transmission jack. 5. Lower the vehicle. 6. Connect the negative cable to the battery. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3495 Transmission Position Switch/Sensor: Description and Operation TRANSMISSION PARK/NEUTRAL SWITCH-PCM INPUT The park/neutral switch is located on the transmission housing and provides an input to the Powertrain Control Module (PCM), This will indicate that the automatic transmission is in Park, Neutral or a drive gear selection. This input is used to determine idle speed (varying with gear selection), fuel injector pulse width, ignition timing advance and vehicle speed control operation. The center terminal of the park/neutral position switch is the starter-circuit terminal. It provides the ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. The outer terminals on the switch are for the backup lamp circuit. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3496 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Sensor Mounting ................................................................................................................................. ..................................................... 27 Nm (20 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 3503 Output Shaft Speed Sensor, Park/Neutral Switch, Transmission Solenoid 8-Way Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 3504 Output Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input Transmission Speed Sensor: Description and Operation Output Shaft Speed Sensor-PCM Input This sensor generates a signal to the PCM relating to the speed of the transmission main drive shaft. NOTE: This input is used with 4-speed electronic transmissions only. CIRCUIT OPERATION Four Speed Automatic Transmission The output shaft speed sensor generates a signal indicating the speed of the transmission output shaft. Circuits T13 and T14 connect the sensor to the Powertrain Control Module (PCM). Circuit T13 connects to cavity B25 of the PCM. Circuit T14 connects to cavity B28. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input > Page 3507 Transmission Speed Sensor: Description and Operation Sensor Operation The speed sensor is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. The vehicle speed sensor also serves as a backup for the transmission speed sensor. Signals from this sensor are shared with the powertrain control module. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 3508 Transmission Speed Sensor: Service and Repair Removal Transmission Speed Sensor Removal Installation 1. Remove transmission speed sensor and O-ring seal from overdrive case. Installation 1. Install transmission speed sensor and O-ring seal in overdrive case. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 3512 Transmission Temperature Sensor/Switch: Description and Operation TRANSMISSION TEMPERATURE SENSOR-PCM INPUT This input is used in the shift operation for 4-speed electronic transmissions only. The temperature data is used for: torque converter clutch operation, overdrive shift, low temperature shift compensation, wide open throttle shift strategy and governor pressure transducer calibration. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations Transmission Solenoids Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > Hydraulic Control System Valve Body: Description and Operation Hydraulic Control System OVERVIEW The hydraulic control system provides fully automatic operation. The system performs five basic functions which are: pressure supply, pressure regulation, flow control, clutch/band application, and lubrication. PRESSURE REGULATION The pressure regulator valve maintains line pressure. The amount of pressure developed is controlled by throttle pressure which is dependent on the degree of throttle opening. The regulator valve is located in the valve body. The throttle valve determines line pressure and shift speed. Governor pressure increases in proportion to vehicle speed. The throttle valve controls upshift and downshift speeds by regulating pressure according to throttle position. Shift Valve Flow Control The manual valve is operated by the gearshift linkage and provides the operating range selected by the driver. The 1-2 shift valve provides 1-2 or 2-1 shifts and the 2-3 shift valve provides 2-3 or 3-2 shifts. The kickdown valve provides forced 3-2 or 3-1 downshifts depending on vehicle speed. Downshifts occur when the throttle is opened beyond downshift detent position. Detent is reached just before wide open throttle position. The 2-3 valve throttle pressure plug provides 3-2 downshifts at varying throttle openings depending on vehicle speed. The 1-2 shift control valve transmits 1-2 shift pressure to the accumulator piston. This controls kickdown band capacity on 1-2 upshifts and 3-2 downshifts. The 3-4 shift, quick fill, and timing valves plus the 3-4 accumulator, are only actuated when the overdrive solenoid is energized. The solenoid contains a check ball that controls a vent port to the 3-4 valves. The check ball either diverts line pressure away from or directly to the 3-4 valves. The limit valve determines maximum speed at which a 3-2 part throttle kickdown can be made. On transmissions without a limit valve, maximum speed for a 3-2 kickdown is at detent position. The 2-3 shuttle valve has two functions. The first is fast front band release and smooth engagement during lift-foot 2-3 upshifts. The second is to regulate front clutch and band application during 3-2 downshifts. The 3-4 timing valve is moved by line pressure coming through the 3-4 shift valve. The timing valve holds the 2-3 shift valve in an upshift position. The purpose is to prevent the 2-3 valve from up or downshifting before the 3-4 valve. The 3-4 accumulator is mounted on the overdrive housing and performs the same function as the 2-3 accumulator; it is used to smooth engagement during a 3-4 shift. The switch valve directs fluid apply pressure to the converter clutch in one position and releases it in the opposite position. It also directs oil to the cooling and lube circuits. The switch valve regulates oil pressure to the torque converter by limiting maximum oil pressure to 130 psi. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > Hydraulic Control System > Page 3518 Valve Body: Description and Operation Shift Valve Operation The shift valves are moved by a combination of throttle and governor pressure. The governor pressure is generated by electrical components. The conditions under which a shift to fourth will not occur are: Overdrive switch is Off - Transmission fluid temperature is below 10 °C (50 °F) or above 121 °C (250 °F) - Shift to third not yet completed - Vehicle speed too low for 3-4 shift to occur - Battery temperature below -5 °F. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > Page 3519 Valve Body: Adjustments CONTROL PRESSURE ADJUSTMENTS There are two control pressure adjustments on the valve body; Line Pressure - Throttle Pressure Line and throttle pressures are interdependent because each affects shift quality and timing. As a result, both adjustments must be performed properly and in the correct sequence. Adjust line pressure first and throttle pressure last. LINE PRESSURE ADJUSTMENT Fig. 260 Measure distance from the valve body to the inner edge of the adjusting screw with an accurate steel scale (Fig. 260). Distance should be 33.4 mm (1-5/16 inch). If adjustment is required, turn the adjusting screw in, or out, to obtain required distance setting. NOTE: The 33.4 mm (1-5/16 inch) setting is an approximate setting. Manufacturing tolerances may make it necessary to vary from this dimension to obtain desired pressure. One complete turn of the adjusting screw changes line pressure approximately 1-2/3 psi (9 kPa). Turning the adjusting screw counterclockwise increases pressure while turning the screw clockwise decreases pressure. THROTTLE PRESSURE ADJUSTMENT Fig. 261 Insert Gauge Tool C-3763 between the throttle lever cam and the kickdown valve stem (Fig. 261). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > Page 3520 Push the gauge tool inward to compress the kickdown valve against the spring and bottom the throttle valve. Maintain pressure against kickdown valve spring. Turn throttle lever stop screw until the screw head touches throttle lever tang and the throttle lever cam touches gauge tool. NOTE: The kickdown valve spring must be fully compressed and the kickdown valve completely bottomed to obtain correct adjustment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 OVERVIEW 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. Refer to Disassembly and Assembly for proper procedures. The only replaceable valve body components are: Manual lever. - Manual lever washer, seal, E-clip, and shaft seal. - Manual lever detent ball. - Throttle lever. - Fluid filter. - Pressure adjusting screw bracket. - Governor pressure solenoid. - Governor pressure sensor. - Converter clutch/overdrive solenoid assembly and harness (includes sump temperature thermistor). - Governor housing gasket. - Solenoid case connector O-rings. The remaining valve body components are serviced only as part of a complete valve body assembly. REMOVAL 1. Shift transmission into NEUTRAL. 2. Raise vehicle. 3. Remove gearshift and throttle levers from shaft of valve body manual lever. Fig. 27 4. Disconnect wires at solenoid case connector (Fig. 27). 5. Position drain pan under transmission oil pan. 6. Remove transmission oil pan and gasket. 7. Remove fluid filter from valve body. 8. Remove bolts attaching valve body to transmission case. 9. Lower valve body enough to remove accumulator piston and springs. 10. Work manual lever shaft and electrical connector out of transmission case. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3523 Fig. 28 11. Lower valve body, rotate valve body away from case, pull park rod out of sprag, and remove valve body (Fig. 28). INSTALLATION Fig. 29 1. Check condition of O-ring seals on valve body harness connector (Fig. 29). Replace seals on connector body if cut or worn. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3524 Fig. 30 2. Check condition of manual lever shaft seal in transmission case. Replace seal if lip is cut or worn. Install new seal with 15/16 deep well socket (Fig. 30). Fig. 31 3. Check condition of seals on accumulator piston (Fig. 31). Install new piston seals, if necessary. 4. Place valve body manual lever in low (1 position) so ball on park lock rod will be easier to install in sprag. 5. Lubricate shaft of manual lever with petroleum jelly. This will ease inserting shaft through seal in case. 6. Lubricate seal rings on valve body harness connector with petroleum jelly. 7. Position valve body in case and work end of park lock rod into and through pawl sprag. Turn propeller shaft to align sprag and park lock teeth if necessary. The rod will click as it enters pawl. Move rod to check engagement. CAUTION: It is possible for the park rod to displace into a cavity just above the pawl sprag during installation. Make sure the rod is actually engaged in the pawl and has not displaced into this cavity. 8. Install accumulator springs and piston into case. Then swing valve body over piston and outer spring to hold it in place. 9. Align accumulator piston and outer spring, manual lever shaft and electrical connector in case. 10. Then seat valve body in case and install one or two bolts to hold valve body in place. 11. Tighten valve body bolts alternately and evenly to 11 Nm (100 inch lbs.) torque. 12. Install new fluid filter on valve body. Tighten filter screws to 4 Nm (35 inch lbs.) torque. 13. Install throttle and gearshift levers on valve body manual lever shaft. 14. Check and adjust front and rear bands if necessary. 15. Connect solenoid case connector wires. 16. Install oil pan and new gasket. Tighten pan bolts to 17 Nm (13 ft. lbs.) torque. 17. Lower vehicle and fill transmission with MOPAR ATF+4, type 9602 fluid. 18. Check and adjust gearshift and throttle valve Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3525 Valve Body: Service and Repair Disassembly Lower Housing Disassembly 1. Remove timing valve cover. 2. Remove 3-4 timing valve and spring. 3. Remove 3-4 quick fill valve, spring and plug. 4. Remove 3-4 shift valve and spring. Lower Housing Shift Valves And Springs 5. Remove converter clutch valve, spring and plug. 6. Remove converter clutch timing valve, retainer and valve spring. Main Component Body CAUTION: Do not clamp any valve body component in a vise. This practice can damage the component resulting in unsatisfactory operation after assembly and installation. Do not use pliers to remove any of the valves, plugs or springs and do not force any of the components out or into place. The valves and valve body housings will be damaged if force is used. Tag or mark the valve body springs for reference as they are removed. Do not allow them to become intermixed. 1. Remove fluid filter. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3526 Governor Pressure Solenoid And Sensor Wire Locations 2. Disconnect wires from governor pressure sensor and solenoid. Governor Body And Retainer Plate Attaching Screw 3. Remove screws attaching governor body and retainer plate to transfer plate. Governor Body And Gasket 4. Remove retainer plate, governor body and gasket from transfer plate. 5. Disconnect wires from governor pressure sensor, if not done previously. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3527 Governor Pressure Sensor 6. Remove governor pressure sensor from governor body. Sensor is retained in body with M-shaped spring clip. Remove clip with small pointed tool and slide sensor out of body. Governor Pressure Solenoid 7. Remove governor pressure solenoid by pulling it straight out of bore in governor body. Remove and discard solenoid O-rings if worn, cut, or torn. 8. Remove transmission fluid filter. Solenoid Harness Case Connector Shoulder Bolt 9. Remove small shoulder bolt that secures solenoid harness case connector to 3-4 accumulator housing. Retain shoulder bolt. Either tape it to harness or thread it back into accumulator housing after connector removal. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3528 Unhooking Solenoid Harness From Accumulator Cover Plate 10. Unhook overdrive/converter solenoid harness from 3-4 accumulator cover plate. Solenoid Assembly Screws 11. Turn valve body over and remove screws that attach overdrive/converter solenoid assembly to valve body. Solenoid Assembly 12. Remove solenoid and harness assembly from valve body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3529 Boost Valve Cover Location 13. Remove boost valve cover. Boost Valve Components 14. Remove boost valve retainer, valve spring and boost valve. Detent Ball And Spring 15. Secure detent ball and spring with Retainer Tool 6583. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3530 Park Rod 16. Remove park rod E-clip and separate rod from manual lever. Throttle Lever E-Clip And Washer 17. Remove E-clip and washer that retains throttle lever shaft in manual lever. Manual And Throttle Lever 18. Remove manual lever and throttle lever. Rotate and lift manual lever off valve body and throttle lever shaft. Then slide throttle lever out of valve body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3531 Detent Ball And Spring 19. Position pencil magnet next to detent housing to catch detent ball and spring. Then carefully remove Retainer Tool 6583 and remove detent ball and spring. Adjusting Screw Bracket Fastener 20. Remove screws attaching pressure adjusting screw bracket to valve body and transfer plate. Hold bracket firmly against spring tension while removing last screw. Adjusting Screw Bracket And Spring 21. Remove adjusting screw bracket, line pressure adjusting screw, pressure regulator valve spring and switch valve spring. Do not remove throttle pressure adjusting screw from bracket and do not disturb setting of either adjusting screw during removal. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3532 Upper Housing Control Valve Locations 22. Turn upper housing over and remove switch valve, regulator valve and spring, and manual valve. 23. Remove kickdown detent, kickdown valve, and throttle valve and spring. Accumulator Housing Screw Locations 24. Loosen left-side 3-4 accumulator housing attaching screw about 2-3 threads. Then remove center and right-side housing attaching screws. Shift And Converter Clutch Valve Springs And Plug 25. Carefully rotate 3-4 accumulator housing upward and remove 3-4 shift valve spring and converter clutch valve plug and spring. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3533 Accumulator Housing, Valve Springs And Plug 26. Remove left-side screw and remove 3-4 accumulator housing from valve body. Boost Valve Tube Brace 27. Bend back tabs on boost valve tube brace. Boost Valve Tube 28. Remove boost valve connecting tube. Disengage tube from upper housing port first. Then rock opposite end of tube back and forth to work it out of lower housing. CAUTION: Do not use tools to loosen or pry the connecting tube out of the valve body housings. Loosen and remove the tube by hand only. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3534 Lower Housing 29. Turn valve body over so lower housing is facing upward. In this position, the two check balls in upper housing will remain in place and not fall out when lower housing and separator plate are removed. 30. Remove screws attaching valve body lower housing to upper housing and transfer plate. Note position of boost valve tube brace for assembly reference. 31. Remove lower housing and overdrive separator plate from transfer plate. ECE Check Ball 32. Remove the ECE check ball from the transfer plate. The ECE check ball is approximately 4.8 mm (3/16 inch) in diameter. Transfer Plate 33. Remove transfer plate from upper housing. 34. Turn transfer plate over so upper housing separator plate is facing upward. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3535 Upperhousing Separator Plate 35. Remove upper housing separator plate from transfer plate. Note position of filter in separator plate for assembly reference. Rear Clutch And Rear Servo Check Ball Locations 36. Remove rear clutch and rear servo check balls from transfer plate. Note check ball location for assembly reference. Upper Housing Disassembly Check Ball Locations In Upper Housing 1. Note location of check balls in valve body upper housing. Then remove the one large diameter and the six smaller diameter check balls. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3536 Shuttle Valve E-Clip And Secondary Spring Location 2. Remove governor plug and shuttle valve covers. Shuttle And Boost Valve Components 3. Remove E-clip that secures shuttle valve secondary spring on valve stem. 4. Remove throttle plug, primary spring, shuttle valve, secondary spring, and spring guides. 5. Remove boost valve retainer, spring and valve if not previously removed. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3537 Upper Housing Control Valve Locations 6. Remove throttle plug and 1-2 and 2-3 governor plugs. Upper Housing Shift Valve And Pressure Plug Locations 7. Turn upper housing around and remove limit valve and shift valve covers. 8. Remove limit valve housing. Then remove retainer, spring, limit valve, and 2-3 throttle plug from limit valve housing. 9. Remove 1-2 shift control valve and spring. 10. Remove 1-2 shift valve and spring. 11. Remove 2-3 shift valve and spring from valve body. 12. Remove pressure plug cover. 13. Remove line pressure plug, sleeve, throttle pressure plug and spring. 3-4 Accumulator 1. Remove end plate from housing. 2. Remove piston spring. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3538 Accumulator Housing Components 3. Remove piston. Remove and discard piston seals. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3539 Valve Body: Service and Repair Disassembly and Assembly DISASSEMBLY CAUTION: Do not clamp any valve body component in a vise. This practice can damage the component resulting in unsatisfactory operation after assembly and installation. Do not use pliers to remove any of the valves, plugs or springs and do not force any of the components out or into place. The valves and valve body housings will be damaged if force is used. Tag or mark the valve body springs for reference as they are removed. Do not allow them to become intermixed. 1. Remove fluid filter. Fig. 39 2. Disconnect wires from governor pressure sensor and solenoid (Fig. 39). Fig. 40 3. Remove screws attaching governor body and retainer plate to transfer plate (Fig. 40). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3540 Fig. 41 4. Remove retainer plate, governor body and gasket from transfer plate (Fig. 41). 5. Disconnect wires from governor pressure sensor, if not done previously. Fig. 42 6. Remove governor pressure sensor from governor body. Sensor is retained in body with M-shaped spring clip (Fig. 42). Remove clip with small pointed tool and slide sensor out of body. Fig. 43 7. Remove governor pressure solenoid by pulling it straight out of bore in governor body (Fig. 43). Remove and discard solenoid O-rings if worn, cut, or torn. 8. Remove transmission fluid filter. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3541 Fig. 44 9. Remove small shoulder bolt that secures solenoid harness case connector to 3-4 accumulator housing (Fig. 44). Retain shoulder bolt. Either tape it to harness or thread it back into accumulator housing after connector removal. Fig. 45 10. Unhook overdrive/converter solenoid harness from 3-4 accumulator cover plate (Fig. 45). Fig. 46 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3542 11. Turn valve body over and remove screws that attach overdrive/converter solenoid assembly to valve body (Fig. 46). Fig. 47 12. Remove solenoid and harness assembly from valve body (Fig. 47). Fig. 48 13. Remove boost valve cover (Fig. 48). Fig. 49 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3543 14. Remove boost valve retainer, valve spring and boost valve (Fig. 49). Fig. 50 15. Secure detent ball and spring with Retainer Tool 6583 (Fig. 50). Fig. 51 16. Remove park rod E-clip and separate rod from manual lever (Fig. 51). Fig. 52 17. Remove E-clip and washer that retains throttle lever shaft in manual lever (Fig. 52). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3544 Fig. 53 18. Remove manual lever and throttle lever (Fig. 53). Rotate and lift manual lever off valve body and throttle lever shaft. Then slide throttle lever out of valve body. Fig. 54 19. Position pencil magnet next to detent housing to catch detent ball and spring. Then carefully remove Retainer Tool 6583 and remove detent ball and spring (Fig. 54). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3545 Fig. 55 20. Remove screws attaching pressure adjusting screw bracket to valve body and transfer plate (Fig. 55). Hold bracket firmly against spring tension while removing last screw. Fig. 56 21. Remove adjusting screw bracket, line pressure adjusting screw, pressure regulator valve spring and switch valve spring (Fig. 56). Do not remove throttle pressure adjusting screw from bracket and do not disturb setting of either adjusting screw during removal. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3546 Fig. 57 22. Turn upper housing over and remove switch valve, regulator valve and spring, and manual valve (Fig. 57). 23. Remove kickdown detent kickdown valve, and throttle valve and spring. Fig. 58 24. Loosen left-side 3-4 accumulator housing attaching screw about 2-3 threads. Then remove center and right-side housing attaching screws (Fig. 58). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3547 Fig. 59 25. Carefully rotate 3-4 accumulator housing upward and remove 3-4 shift valve spring and converter clutch valve plug and spring (Fig. 59). Fig. 60 26. Remove left-side screw and remove 3-4 accumulator housing from valve body (Fig. 60). Fig. 61 27. Bend back tabs on boost valve tube brace (Fig. 61). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3548 Fig. 62 28. Remove boost valve connecting tube (Fig. 62). Disengage tube from upper housing port first. Then rock opposite end of tube back and forth to work it out of lower housing. CAUTION: Do not use tools to loosen or pry the connecting tube out of the valve body housings. Loosen and remove the tube by hand only. Fig. 63 29. Turn valve body over so lower housing is facing upward (Fig. 63). In this position, the two check balls in upper housing will remain in place and not fall out when lower housing and separator plate are removed. 30. Remove screws attaching valve body lower housing to upper housing and transfer plate. Note position of boost valve tube brace for assembly reference. 31. Remove lower housing and overdrive separator plate from transfer plate. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3549 Fig. 64 32. Remove the ECE check ball from the transfer plate (Fig. 64). The ECE check ball is approximately 4.8 mm (3/16 inch) in diameter. Fig. 65 33. Remove transfer plate from upper housing (Fig. 65). 34. Turn transfer plate over so upper housing separator plate is facing upward. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3550 Fig. 66 35. Remove upper housing separator plate from transfer plate (Fig. 66). Note position of filter in separator plate for assembly reference. Fig. 67 36. Remove rear clutch and rear servo check balls from transfer plate. Note check ball location for assembly reference (Fig. 67). VALVE BODY UPPER HOUSING Fig. 68 1. Note location of check balls in valve body upper housing (Fig. 68). Then remove the one large diameter and the six smaller diameter check balls. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3551 Fig. 70 2. Remove governor plug and shuttle valve covers (Fig. 69). Fig. 69 3. Remove E-clip that secures shuttle valve secondary spring on valve stem (Fig. 70). 4. Remove throttle plug, primary spring, shuttle valve, secondary spring, and spring guides. 5. Remove boost valve retainer, spring and valve if not previously removed. 6. Remove throttle plug and 1-2 and 2-3 governor plugs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3552 Fig. 71 7. Turn upper housing around and remove limit valve and shift valve covers (Fig. 71). 8. Remove limit valve housing. Then remove retainer, spring, limit valve, and 2-3 throttle plug from limit valve housing. 9. Remove 1-2 shift control valve and spring. 10. Remove 1-2 shift valve and spring. 11. Remove 2-3 shift valve and spring from valve body. 12. Remove pressure plug cover. 13. Remove line pressure plug, sleeve, throttle pressure plug and spring. VALVE BODY LOWER HOUSING 1. Remove timing valve cover. 2. Remove 3-4 timing valve and spring. 3. Remove 3-4 quick fill valve, spring and plug. 4. Remove 3-4 shift valve and spring. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3553 Fig. 72 5. Remove converter clutch valve, spring and plug (Fig. 72). 6. Remove converter clutch timing valve, retainer and valve spring. 3-4 ACCUMULATOR HOUSING 1. Remove end plate from housing. 2. Remove piston spring. Fig. 73 3. Remove piston. Remove and discard piston seals (Fig. 73). ASSEMBLY Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3554 CAUTION: Do not force valves or plugs into place during reassembly. If the valve body bores, valves and plugs are free of distortion or burrs, the valve body components should all slide into place easily. In addition, do not overtighten the transfer plate and valve body screws during reassembly. Overtightening can distort the housings resulting in valve sticking, cross leakage and unsatisfactory operation. Tighten valve body screws to recommended torque only. LOWER HOUSING 1. Lubricate valves, springs, and the housing valve and plug bores with clean transmission fluid. 2. Install 3-4 timing valve spring and valve in lower housing. 3. Install 3-4 quick fill valve in lower housing. 4. Install 3-4 quick fill valve spring and plug in housing. 5. Install timing valve end plate. Tighten end plate screws to 4 Nm (35 inch lbs.) torque. 3-4 ACCUMULATOR 1. Lubricate accumulator piston, seals and housing piston bore with clean transmission fluid. 2. Install new seal rings on accumulator piston. 3. Install piston and spring in housing. 4. Install end plate on housing. TRANSFER PLATE Fig. 74 1. Install rear clutch and rear servo check balls in transfer plate (Fig. 74). Fig. 75 2. Install filter screen in upper housing separator plate (Fig. 75). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3555 Fig. 76 3. Align and position upper housing separator plate on transfer plate (Fig. 76). 4. Install brace plate. Tighten brace attaching screws to 4 Nm (35 inch lbs.) torque. 5. Install remaining separator plate attaching screws. Tighten screws to 4 Nm (35 inch lbs.) torque. UPPER AND LOWER HOUSING Fig. 77 1. Position upper housing so internal passages and check ball seats are facing upward. Then install check balls in housing (Fig. 77). Eight check balls are used. The single large check ball is approximately 8.7 mm (11/32 inch) diameter. The single small check ball is approximately 4.8 mm (3/16 inch) in diameter. The remaining 6 check balls are approximately 6.3 mm (1/4 in in diameter.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3556 Fig. 78 2. Position assembled transfer plate and upper housing separator plate on upper housing (Fig. 78). 3. Install the ECE check ball into the transfer plate. The ECE check ball is approximately 4.8 mm (3/16 inch) in diameter. Fig. 79 4. Position lower housing separator plate on transfer plate (Fig. 79). Fig. 80 5. Install lower housing on assembled transfer plate and upper housing (Fig. 80). 6. Install and start all valve body screws by hand except for the screws to hold the boost valve tube brace. Save those screws for later installation. Then tighten screws evenly to 4 Nm (35 inch lbs.) torque. Start at center and work out to sides when tightening screws. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3557 UPPER HOUSING VALVE AND PLUG Fig. 81 Fig. 82 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3558 Fig. 83 Refer to (Figs. 81, 82 and 83) to perform the following steps. 1. Lubricate valves, plugs, springs with clean transmission fluid. 2. Assemble regulator valve line pressure plug, sleeve, throttle plug and spring. Insert assembly in upper housing and install cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 3. Install 1-2 and 2-3 shift valves and springs. 4. Install 1-2 shift control valve and spring. 5. Install retainer, spring, limit valve, and 2-3 throttle plug from limit valve housing. 6. Install limit valve housing and cover plate. Tighten screws to 4 Nm (35 inch lbs.). 7. Install shuttle valve as follows: a. Insert plastic guides in shuttle valve secondary spring and install spring on end of valve. b. Install shuttle valve into housing. c. Hold shuttle valve in place. d. Compress secondary spring and install E-clip in groove at end of shuttle valve. e. Verify that spring and E-clip are properly seated before proceeding. 8. Install shuttle valve cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 9. Install 1-2 and 2-3 valve governor plugs in valve body. 10. Install shuttle valve primary spring and throttle plug. 11. Align and install governor plug cover. Tighten cover screws to 4 Nm (35 inch lbs.) torque. BOOST VALVE TUBE AND BRACE Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3559 Fig. 84 1. Position valve body assembly so lower housing is facing upward (Fig. 84). 2. Lubricate tube ends and housing ports with transmission fluid or petroleum jelly. 3. Start tube in lower housing port first. Then swing tube downward and work opposite end of tube into upper housing port. 4. Insert and seat each end of tube in housings. Fig. 85 5. Slide tube brace under tube and into alignment with valve body screw holes (Fig. 85). 6. Install and finger tighten three screws that secure tube brace to valve body housings. Fig. 86 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3560 7. Bend tube brace tabs up and against tube to hold it in position (Fig. 86). 8. Tighten all valve body housing screws to 4 Nm (35 inch lbs.) torque after tube and brace are installed. Tighten screws in diagonal pattern starting at center and working outward. 3-4 ACCUMULATOR Fig. 87 1. Position converter clutch valve and 3-4 shift valve springs in housing (Fig. 87). 2. Loosely attach accumulator housing with rightside screw. Install only one screw at this time as accumulator must be free to pivot upward for ease of installation. 3. Install 3-4 shift valve and spring. 4. Install converter clutch timing valve and spring. 5. Position plug on end of converter clutch valve spring. Then compress and hold springs and plug in place with fingers of one hand. 6. Swing accumulator housing upward over valve springs and plug. Fig. 88 7. Hold accumulator housing firmly in place and install remaining two attaching screws. Be sure springs and clutch valve plug are properly seated (Fig. 88). Tighten screws to 4 Nm (35 inch lbs.) VALVE BODY FINAL 1. Install boost valve, valve spring, retainer and cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 2. Insert manual lever detent spring in upper housing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3561 Fig. 89 3. Position detent ball on end of spring. Then hold detent ball and spring in detent housing with Retainer Tool 6583 (Fig. 89). 4. Install throttle lever in upper housing. Then install manual lever over throttle lever and start manual lever into housing. 5. Align manual lever with detent ball and manual valve. Hold throttle lever upward. Then press down on manual lever until fully seated. Remove detent ball retainer tool after lever is seated. 6. Then install manual lever seal, washer and E-clip. Fig. 90 7. Verify that throttle lever is aligned with end of kickdown valve stem and that manual lever arm is engaged in manual valve (Fig. 90). 8. Position line pressure adjusting screw in adjusting screw bracket. 9. Install spring on end of line pressure regulator valve. 10. Install switch valve spring on tang at end of adjusting screw bracket. 11. Install manual valve. 12. Install throttle valve and spring. 13. Install kickdown valve and detent. 14. Install pressure regulator valve. 16. Install switch valve. 16. Position adjusting screw bracket on valve body. Align valve springs and press bracket into place. Install short, upper bracket screws first and long bottom screw last. Verify that valve springs and bracket are properly aligned. Then tighten all three bracket screws to 4 Nm (35 inch lbs.) torque. 17. Lubricate solenoid case connector O-rings and shaft of manual lever with light coat of petroleum jelly. 18. Obtain new fluid filter for valve body but do not install filter at this time. 19. If line pressure and/or throttle pressure adjustment screw settings were not disturbed, continue with overhaul or reassembly. However, if adjustment screw settings were moved or changed, readjust as described in Valve Body Control Pressure Adjustment procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3562 Fig. 91 20. Attach solenoid case connector to 3-4 accumulator with shoulder-type screw. Connector has small locating tang that fits in dimple at top of accumulator housing (Fig. 91). Seat tang in dimple before tightening connector screw. 21. Install solenoid assembly and gasket. Tighten solenoid attaching screws to 8 Nm (72 inch lbs.) torque. Fig. 92 22. Verify that solenoid wire harness is properly routed (Fig. 92). Solenoid harness must be clear of manual lever and park rod and not be pinched between accumulator housing and cover. GOVERNOR BODY, SENSOR AND SOLENOID 1. Turn valve body assembly over so accumulator side of transfer plate is facing down. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3563 Fig. 93 2. Install new O-rings on governor pressure solenoid and sensor (Fig. 93). 3. Lubricate solenoid and sensor O-rings with clean transmission fluid. 4. Install governor pressure sensor in governor body. Then secure sensor with M-shaped retaining clip. Fig. 94 5. Install governor pressure solenoid in governor body (Fig. 94). Push solenoid in until it snaps into place in body. Fig. 95 6. Position governor body gasket on transfer plate (Fig. 95). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3564 Fig. 96 7. Install retainer plate on governor body and around solenoid (Fig. 96). Be sure solenoid connector is positioned in retainer cutout. 8. Align screw holes in governor body and transfer plate. Then install and tighten governor body screws to 4 Nm (35 inch lbs.) torque. Fig. 97 9. Connect harness wires to governor pressure solenoid and governor pressure sensor (Fig. 97). 10. Perform Line Pressure and Throttle Pressure adjustments, refer to Adjustments for proper procedures. 11. Install fluid filter and pan. 12. Lower vehicle. 13. Fill transmission with recommended fluid and road test vehicle to verify repair. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3565 Valve Body: Service and Repair Cleaning and Inspection Clean the valve housings, valves, plugs, springs, and separator plates with a standard parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution. Do not immerse any of the electrical components in cleaning solution. Clean the governor solenoid and sensor and the dual solenoid and harness assembly by wiping them off with dry shop towels only. Dry all except the electrical parts with compressed air. Make sure all passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint from these materials can stick to valve body parts, interfere with valve operation, and clog filters and fluid passages. Wipe the governor pressure sensor and solenoid valve with dry, lint free shop towels only. The O-rings on the sensor and solenoid valve are the only serviceable components. Be sure the vent ports in the solenoid valve are open and not blocked by dirt or debris. Replace the valve and/or sensor only when DRB scan tool diagnosis indicates this is necessary. Or, if either part has sustained physical damage (dented, deformed, broken, etc.). CAUTION: Do not turn the small screw at the end of the solenoid valve for any reason. Turning the screw in either direction will ruin solenoid calibration and result in solenoid failure. In addition, the filter on the solenoid valve is NOT serviceable. Do not try to remove the filter as this will damage the valve housing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3566 Fig. 251 Inspect the throttle and manual valve levers and shafts (Fig. 251). Do not attempt to straighten a bent shaft or correct a loose lever. Replace these components if worn, bent, loose or damaged in any way. Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure. Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally flat surface. If distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3567 CAUTION: Many of the valves and plugs, such as the throttle valve, shuttle valve plug, 1-2 shift valve and 1-2 governor plug, are made of coated aluminum. Aluminum components are identified by the dark color of the special coating applied to the surface (or by testing with a magnet). Do not sand aluminum valves or plugs under any circumstances. This practice could damage the special coating causing the valves/plugs to stick and bind. Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore. Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils. Check the two separator plates for distortion or damage of any kind. Inspect the upper housing, lower housing, 3-4 accumulator housing, and transfer plate carefully. Be sure all fluid passages are clean and clear. Check condition of the upper housing and transfer plate check balls as well. The check balls and ball seats must not be worn or damaged. Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores. Valve body bores do not change dimensionally with use. If the valve body functioned correctly when new, it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling. The only serviceable valve body components are listed below. The remaining valve body components are serviced only as part of a complete valve body assembly. Serviceable parts are: dual solenoid and harness assembly - solenoid gasket - solenoid case connector O-rings and shoulder bolt - switch valve and spring - pressure adjusting screw and bracket assembly - throttle lever - manual lever and shaft seal - throttle lever shaft seal, washer, and E-clip - fluid filter and screws - detent ball and spring - valve body screws - governor pressure solenoid - governor pressure sensor and retaining clip - park lock rod and E-clip Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3568 Valve Body: Service and Repair Assembly Assembly Precaution CAUTION: Do not force valves or plugs into place during reassembly. If the valve body bores, valves and plugs are free of distortion or burrs, the valve body components should all slide into place easily. In addition, do not overtighten the transfer plate and valve body screws during reassembly. Overtightening can distort the housings resulting in valve sticking, cross leakage and unsatisfactory operation. Tighten valve body screws to recommended torque only. NOTE: Follow assembly steps in order shown for proper valve body assembly. Boost Valve and Brace Assembly Boost Valve Tube 1. Position valve body assembly so lower housing is facing upward. 2. Lubricate tube ends and housing ports with transmission fluid or petroleum jelly. 3. Start tube in lower housing port first. Then swing tube downward and work opposite end of tube into upper housing port. 4. Insert and seat each end of tube in housings. Boost Valve Tube And Brace 5. Slide tube brace under tube and into alignment with valve body screw holes. 6. Install and finger tighten three screws that secure tube brace to valve body housings. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3569 Securing Boost Valve Tube With Brace Tabs 7. Bend tube brace tabs up and against tube to hold it in position. 8. Tighten all valve body housing screws to 4 Nm (35 inch lbs.) torque after tube and brace are installed. Tighten screws in diagonal pattern starting at center and working outward. Governor Body, Sensor and Solenoid Assembly 1. Turn valve body assembly over so accumulator side of transfer plate is facing down. Governor Pressure Sensor 2. Install new O-rings on governor pressure solenoid and sensor. 3. Lubricate solenoid and sensor O-rings with clean transmission fluid. 4. Install governor pressure sensor in governor body. Then secure sensor with M-shaped retaining clip. Governor Pressure Solenoid 5. Install governor pressure solenoid in governor body. Push solenoid in until it snaps into place in body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3570 Governor Body And Gasket 6. Position governor body gasket on transfer plate. Pressure Solenoid Retainer 7. Install retainer plate on governor body and around solenoid. Be sure solenoid connector is positioned in retainer cutout. 8. Align screw holes in governor body and transfer plate. Then install and tighten governor body screws to 4 Nm (35 inch lbs.) torque. Governor Pressure Sensor And Solenoid Connectors 9. Connect harness wires to governor pressure solenoid and governor pressure sensor. 10. Perform Line Pressure and Throttle Pressure adjustments, refer to adjustment section for proper procedures. 11. Install fluid filter and pan. 12. Lower vehicle. 13. Fill transmission with recommended fluid and road test vehicle to verify repair. Lower Housing Disassembly Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3571 Lower Housing Shift Valves And Springs 1. Lubricate valves, springs, and the housing valve and plug bores with clean transmission fluid. 2. Install 3-4 timing valve spring and valve in lower housing. 3. Install 3-4 quick fill valve in lower housing. 4. Install 3-4 quick fill valve spring and plug in housing. 5. Install timing valve end plate. Tighten end plate screws to 4 Nm (35 inch lbs.) torque. Transfer Plate Assembly Rear Clutch And Rear Servo Sheck Ball Locations 1. Install rear clutch and rear servo check balls in transfer plate. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3572 Seperator Plate Filter Screen Installation 2. Install filter screen in upper housing separator plate. Brace Plate 3. Align and position upper housing separator plate on transfer plate. 4. Install brace plate. Tighten brace attaching screws to 4 Nm (35 inch lbs.) torque. 5. Install remaining separator plate attaching screws. Tighten screws to 4 Nm (35 inch lbs.) torque. Upper and Lower Housing Assembly Check Ball Locations In Upper Housing 1. Position upper housing so internal passages and check ball seats are facing upward. Then install check balls in housing. Eight check balls are used. The single large check ball is approximately 8.7 mm (11/32 inch) diameter. The single small check ball is approximately 4.8 mm (3/16 inch) in diameter. The remaining 6 check balls are approximately 6.3 mm (1/4 inch) in diameter. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3573 Installing Transfer Plate On Upper Housing 2. Position assembled transfer plate and upper housing separator plate on upper housing. Be sure filter screen is seated in proper housing recess. ECE Check Ball 3. Install the ECE check ball into the transfer plate. The ECE check ball is approximately 4.8 mm (3/16 inch) in diameter. Lower Housing Separator Plate 4. Position lower housing separator plate on transfer plate. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3574 Installing Lower Housing On Transfer Plate And Upper Housing 5. Install lower housing on assembled transfer plate and upper housing. 6. Install and start all valve body screws by hand except for the screws to hold the boost valve tube brace. Save those screws for later installation. Then tighten screws evenly to 4 Nm (35 inch lbs.) torque. Start at center and work out to sides when tightening screws. Upper Housing Valve and Plug Assembly Shuttle And Boost Valve Components Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3575 Upper Housing Control Valve Locations Upper Housing Shift Valve And Pressure Plug Locations Refer to figures to perform the following steps. 1. Lubricate valves, plugs, springs with clean transmission fluid. 2. Assemble regulator valve line pressure plug, sleeve, throttle plug and spring. Insert assembly in upper housing and install cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 3. Install 1-2 and 2-3 shift valves and springs. 4. Install 1-2 shift control valve and spring. 5. Install retainer, spring, limit valve, and 2-3 throttle plug from limit valve housing. 6. Install limit valve housing and cover plate. Tighten screws to 4 Nm (35 inch lbs.). 7. Install shuttle valve as follows: a. Insert plastic guides in shuttle valve secondary spring and install spring on end of valve. b. Install shuttle valve into housing. c. Hold shuttle valve in place. d. Compress secondary spring and install E-clip in groove at end of shuttle valve. e. Verify that spring and E-clip are properly seated before proceeding. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3576 8. Install shuttle valve cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 9. Install 1-2 and 2-3 valve governor plugs in valve body. 10. Install shuttle valve primary spring and throttle plug. 11. Align and install governor plug cover. Tighten cover screws to 4 Nm (35 inch lbs.) torque. Valve Body Final Assembly and Adjustment 1. Install boost valve, valve spring, retainer and cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 2. Insert manual lever detent spring in upper housing. Detent Ball Spring 3. Position detent ball on end of spring. Then hold detent ball and spring in detent housing with Retainer Tool 6583. 4. Install throttle lever in upper housing. Then install manual lever over throttle lever and start manual lever into housing. 5. Align manual lever with detent ball and manual valve. Hold throttle lever upward. Then press down on manual lever until fully seated. Remove detent ball retainer tool after lever is seated. 6. Then install manual lever seal, washer and E-clip. Manual And Throttle Lever Alignment 7. Verify that throttle lever is aligned with end of kickdown valve stem and that manual lever arm is engaged in manual valve. 8. Position line pressure adjusting screw in adjusting screw bracket. 9. Install spring on end of line pressure regulator valve. 10. Install switch valve spring on tang at end of adjusting screw bracket. 11. Install manual valve. 12. Install throttle valve and spring. 13. Install kickdown valve and detent. 14. Install pressure regulator valve. 15. Install switch valve. 16. Position adjusting screw bracket on valve body. Align valve springs and press bracket into place. Install short, upper bracket screws first and long bottom screw last. Verify that valve springs and bracket are properly aligned. Then tighten all three bracket screws to 4 Nm (35 inch lbs.) torque. 17. Lubricate solenoid case connector O-rings and shaft of manual lever with light coat of petroleum jelly. 18. Obtain new fluid filter for valve body but do not install filter at this time. 19. If line pressure and/or throttle pressure adjustment screw settings were not disturbed, continue with overhaul or reassembly. However, if adjustment screw settings were moved or changed, readjust as described in Valve Body Control Pressure Adjustment procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3577 Solenoid Harness Case Connector Shoulder Bolt 20. Attach solenoid case connector to 3-4 accumulator with shoulder-type screw. Connector has small locating tang that fits in dimple at top of accumulator housing. Seat tang in dimple before tightening connector screw. 21. Install solenoid assembly and gasket. Tighten solenoid attaching screws to 8 Nm (72 inch lbs.) torque. Solenoid Harness Routing 22. Verify that solenoid wire harness is properly routed. Solenoid harness must be clear of manual lever and park rod and not be pinched between accumulator housing and cover. 3-4 Accumulator Assembly Installation Converter Clutch And 3-4 Shift Valve Springs 1. Position converter clutch valve and 3-4 shift valve springs in housing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3578 2. Loosely attach accumulator housing with right-side screw. Install only one screw at this time as accumulator must be free to pivot upward for ease of installation. 3. Install 3-4 shift valve and spring. 4. Install converter clutch timing valve and spring. 5. Position plug on end of converter clutch valve spring. Then compress and hold springs and plug in place with fingers of one hand. 6. Swing accumulator housing upward over valve springs and plug. Seating 3-4 Accumulator On Lower Housing 7. Hold accumulator housing firmly in place and install remaining two attaching screws. Be sure springs and clutch valve plug are properly seated. Tighten screws to 4 Nm (35 inch lbs.). 3-4 Accumulator Reassembly Accumulator Housing Components 1. Lubricate accumulator piston, seals and housing piston bore with clean transmission fluid. 2. Install new seal rings on accumulator piston. 3. Install piston and spring in housing. 4. Install end plate on housing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Service and Repair > Front Axle Carrier Bearings: Service and Repair Front Axle REMOVAL 1. Remove differential from axle housing. 2. Remove the bearings from the differential case with Puller/Press C-293-PA, C-293-39 Blocks, and Plug SP-3289. INSTALLATION Fig. 21 1. Using tool C-3716-A with handle C-4171, install differential side bearings. 2. Install differential in axle housing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Service and Repair > Front Axle > Page 3585 Carrier Bearings: Service and Repair Rear Axle REMOVAL 1. Remove differential case from axle housing. Fig. 21 Fig. 22 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Service and Repair > Front Axle > Page 3586 2. Remove the bearings from the differential case with Puller/Press C-293-PA and: - Adapters C-293-48 and Plug SP-3289 for the 8 1/4 axle. - Adapters C-293-47 and Plug C-293-3 for the 9 1/4 axle. INSTALLATION Fig. 23 1. Install differential side bearings. Use: - Installer C-4340 with handle C-4171 for the 8 1/4 axle. - Installer C-4213 and Handle C-4171 for the 9 1/4 axle. 2. Install differential case in axle housing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Service and Repair Carrier Side Gears: Service and Repair Refer to Differential, Service and Repair, Disassembly and Assembly for procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Technical Service Bulletins > Differential Cover - Updated Sealer & Fluid Differential Cover: Technical Service Bulletins Differential Cover - Updated Sealer & Fluid NUMBER: 03-08-00 GROUP: Axle & Propeller Shaft DATE: Sep. 5, 2000 SUBJECT: RTV Use On Corporate Axle MODELS: NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH AN 8.25, 9.25, OR C205F CORPORATE AXLE. DISCUSSION: The axle lubricant used in all corporate axles was changed in formulation starting at the beginning of the 1998 model year. The corporate axles involved include: the 8.25 and 9.25 rear axles, and the C205F front axle. The new lubricant in use is SAE 75W-90 p/n 05010320AA. The lubricant change was made as a fuel economy improvement. The new axle lubricant is more chemically aggressive/reactive when in contact with the previous used Room Temperature Vulcanizable (RTV) sealant. Because of this condition, the RTV used in assembly of the pan/cover to the axle housing was revised and improved. When re-sealing axle covers, using the proper sealing material to minimize any potential sealant breakdown is important. The only recommended sealing material for all corporate axle covers is MOPAR RTV Sealant, p/n 05013477M. This RTV is red/orange in color. NOTE: IF SAE 75W-90 LUBRICANT IS USED TO REFILL ANY CORPORATE AXLE, THEN THE RED/ORANGE MOPAR RTV SEALANT, P/N 05013477AA, SHOULD BE USED TO SEAL THE COVER TO THE AXLE HOUSING. To optimize sealant performance and enhance adhesion, flanges should be clean and free of residual lubricant. The mating flanges should first be cleaned of any excess old RTV using a plastic putty knife. Final cleaning/degreasing shall be done by spraying MOPAR Brake Parts Cleaner, p/n 04549623, on the carrier and cover flanges, followed by a wipe with a clean dry cloth. Care should be taken to avoid spraying the parts cleaner inside the carrier. Once the RTV has been applied, the axle cover is to be installed to the housing within 3 to 5 minutes to prevent skinning over of the RTV. NOTE: IF THE AXLE COVER IS NOT INSTALLED WITHIN THE 3 TO 5 MINUTE TIME FRAME, THE CARRIER COVER FACE MUST BE RECLEANED AND NEW RTV APPLIED, OR ADHESION QUALITY WILL BE COMPROMISED. Immediately install the cover attaching bolts and tighten them to the specified torque to prevent a shimming effect by the RTV. POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Technical Service Bulletins > Customer Interest for Differential Axle Housing: > 03-04-99 > Jun > 99 > Front Differential - Vent Leakage Differential Axle Housing: Customer Interest Front Differential - Vent Leakage NUMBER: 03-04-99 GROUP: Axle & Propshaft DATE: June 4, 1999 SUBJECT: Differential gear lubricant is weeping from the front differential vent. OVERVIEW: This bulletin involves installing a differential canister vent in the front differential vent hose. MODELS: 1997 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO 4X4 VEHICLES. SYMPTOM/CONDITION: Differential gear lubricant is weeping from the front differential vent. DIAGNOSIS: Inspect the front differential vent for signs of differential gear lubricant weeping from the vent. If differential gear lubricant is weeping from the front differential vent, perform the Repair Procedure. PARTS REQUIRED: 1 05016306AA Canister, Front Differential Vent AR (1) 04874468 Lubricant, Mopar 80W-90 Gear & Axle 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. Open the hood and locate the front differential vent hose. The hose is located to the right of the radiator (Figure 1). 2. Place a mark on the front differential vent hose 203 mm (8 in.) from the top of the vent, then cut the hose at the mark (Figure 1). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Technical Service Bulletins > Customer Interest for Differential Axle Housing: > 03-04-99 > Jun > 99 > Front Differential - Vent Leakage > Page 3602 3. Place a mark on the front differential vent hose 89 mm (3.5 in.) from the top of the vent, then cut the hose at the mark and discard the cut section of hose (Figure 1). 4. Slide one of the nipples of the front differential vent canister p/n 0501 6306AA onto the lower section of the hose remaining in the vehicle. Make sure the vent hose is pushed completely onto the nipple of the canister by ensuring the hose is over the last barb. 5. Insert the top section of the differential vent hose onto the remaining nipple of the front differential vent canister. Make sure the vent hose is pushed completely onto the nipple of the canister by ensuring the hose is over the last barb. 6. Inspect the level of the front differential lubricant. Fill the differential with SAE 80W-90 Gear Lubricant p/n 04874468. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-60-65-92 0.2 Hrs. FAILURE CODE: P8- New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Axle Housing: > 03-04-99 > Jun > 99 > Front Differential - Vent Leakage Differential Axle Housing: All Technical Service Bulletins Front Differential - Vent Leakage NUMBER: 03-04-99 GROUP: Axle & Propshaft DATE: June 4, 1999 SUBJECT: Differential gear lubricant is weeping from the front differential vent. OVERVIEW: This bulletin involves installing a differential canister vent in the front differential vent hose. MODELS: 1997 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO 4X4 VEHICLES. SYMPTOM/CONDITION: Differential gear lubricant is weeping from the front differential vent. DIAGNOSIS: Inspect the front differential vent for signs of differential gear lubricant weeping from the vent. If differential gear lubricant is weeping from the front differential vent, perform the Repair Procedure. PARTS REQUIRED: 1 05016306AA Canister, Front Differential Vent AR (1) 04874468 Lubricant, Mopar 80W-90 Gear & Axle 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. Open the hood and locate the front differential vent hose. The hose is located to the right of the radiator (Figure 1). 2. Place a mark on the front differential vent hose 203 mm (8 in.) from the top of the vent, then cut the hose at the mark (Figure 1). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Axle Housing: > 03-04-99 > Jun > 99 > Front Differential - Vent Leakage > Page 3608 3. Place a mark on the front differential vent hose 89 mm (3.5 in.) from the top of the vent, then cut the hose at the mark and discard the cut section of hose (Figure 1). 4. Slide one of the nipples of the front differential vent canister p/n 0501 6306AA onto the lower section of the hose remaining in the vehicle. Make sure the vent hose is pushed completely onto the nipple of the canister by ensuring the hose is over the last barb. 5. Insert the top section of the differential vent hose onto the remaining nipple of the front differential vent canister. Make sure the vent hose is pushed completely onto the nipple of the canister by ensuring the hose is over the last barb. 6. Inspect the level of the front differential lubricant. Fill the differential with SAE 80W-90 Gear Lubricant p/n 04874468. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-60-65-92 0.2 Hrs. FAILURE CODE: P8- New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Differential Cover - Updated Sealer & Fluid Fluid - Differential: Technical Service Bulletins Differential Cover - Updated Sealer & Fluid NUMBER: 03-08-00 GROUP: Axle & Propeller Shaft DATE: Sep. 5, 2000 SUBJECT: RTV Use On Corporate Axle MODELS: NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH AN 8.25, 9.25, OR C205F CORPORATE AXLE. DISCUSSION: The axle lubricant used in all corporate axles was changed in formulation starting at the beginning of the 1998 model year. The corporate axles involved include: the 8.25 and 9.25 rear axles, and the C205F front axle. The new lubricant in use is SAE 75W-90 p/n 05010320AA. The lubricant change was made as a fuel economy improvement. The new axle lubricant is more chemically aggressive/reactive when in contact with the previous used Room Temperature Vulcanizable (RTV) sealant. Because of this condition, the RTV used in assembly of the pan/cover to the axle housing was revised and improved. When re-sealing axle covers, using the proper sealing material to minimize any potential sealant breakdown is important. The only recommended sealing material for all corporate axle covers is MOPAR RTV Sealant, p/n 05013477M. This RTV is red/orange in color. NOTE: IF SAE 75W-90 LUBRICANT IS USED TO REFILL ANY CORPORATE AXLE, THEN THE RED/ORANGE MOPAR RTV SEALANT, P/N 05013477AA, SHOULD BE USED TO SEAL THE COVER TO THE AXLE HOUSING. To optimize sealant performance and enhance adhesion, flanges should be clean and free of residual lubricant. The mating flanges should first be cleaned of any excess old RTV using a plastic putty knife. Final cleaning/degreasing shall be done by spraying MOPAR Brake Parts Cleaner, p/n 04549623, on the carrier and cover flanges, followed by a wipe with a clean dry cloth. Care should be taken to avoid spraying the parts cleaner inside the carrier. Once the RTV has been applied, the axle cover is to be installed to the housing within 3 to 5 minutes to prevent skinning over of the RTV. NOTE: IF THE AXLE COVER IS NOT INSTALLED WITHIN THE 3 TO 5 MINUTE TIME FRAME, THE CARRIER COVER FACE MUST BE RECLEANED AND NEW RTV APPLIED, OR ADHESION QUALITY WILL BE COMPROMISED. Immediately install the cover attaching bolts and tighten them to the specified torque to prevent a shimming effect by the RTV. POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Differential Cover - Updated Sealer & Fluid > Page 3613 Fluid - Differential: Technical Service Bulletins Differential - Fluid Discoloration Explanation NUMBER: 03-02-00 GROUP: Axles DATE: Mar.03, 2000 SUBJECT: 9.25 Axle Gear Marking Compound Causes A Milky-Like Appearance To The Axle Fluid MODELS: 1999 - 2000 (AB) Ram Van 1999 - 2000 (AN) Dakota 1999 - 2000 (BR/BE) Ram Truck 1999 - 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 9.25 INCH REAR AXLE AND BUILT BETWEEN NOV. 1, 1998 (MDH 1101XX) AND NOV. 1,1999 (MDH 1101XX). DISCUSSION: The customer or servicing technician may notice a milky-like appearance to the 9.25 inch rear axle fluid. This condition may be brought to the customer's attention when the axle fluid is inspected during normal service. Other than the concern for the color of axle fluid, the customer does not experience any other axle complaint. The customer or servicing technician may be concerned because a milky-like appearance to the axle fluid may also indicate the presence of water. The cause of the milky-like appearance to the axle fluid may be due to the use of a white color gear marking compound during the axle assembly process. Axle gear marking compound is used to verify correct ring and pinion gear alignment during manufacture. The 9.25 inch rear axle is assembled on two different assembly lines. To visually distinguish axles from each assembly line, one assembly line used a white color gear marking compound (versus yellow). Half of the axles that were assembled during the above time frame may have the white gear marking compound mixed with the rear axle fluid. The white color gear marking compound is no longer in use by the axle assembly plant. NOTE: IF THE MILKY-LIKE REAR AXLE FLUID APPEARANCE IS DUE TO THE WHITE GEAR MARKING COMPOUND, THEN NO SERVICE ACTION IS NECESSARY TO ADDRESS THIS CONDITION. If the milky-like rear axle fluid appearance is due to the presence of water, then the rear axle will require service. Axle fluid, contaminated with water, may cause rust and damage to the internal components of the axle. Any water in the axle fluid will begin to boil off (reach its gaseous state) before the oil. Placing a small sample of axle fluid on a hot steel surface (around 100C or 212F) will cause any water that may be present in the fluid to boil off with a "sizzle-like" sound. POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front Axle - 194FIA Differential Oil Capacity Lube Capacity ...................................................................................................................................... ............................................... 1.72 liters (3.60 pints) 8 1/4 Axle Differential Oil Capacity Lube Capacity ...................................................................................................................................... ................................................ 2.22 Liters (4.7 pints) Trac-lok Additive .............................................. ........................................................................................................................................ 148 ml (5 ounces) 9 1/4 Axle Differential Oil Capacity Lube Capacity ...................................................................................................................................... ................................................ 2.32 Liters (4.9 pints) Trac-lok Additive .............................................. ........................................................................................................................................ 148 ml (5 ounces) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 3616 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Grade ................................................................................................................................................... ................................................................... API GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 If equipped with TRAC-LOK, include the specified amount of friction modifier. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Page 3617 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Front Axle Fluid - Differential: Service and Repair Front Axle 1. Raise and support the vehicle. 2. Remove the lubricant fill hole plug from the differential housing cover. 3. Remove the differential housing cover and drain the lubricant from the housing. 4. Clean the housing cavity with a flushing oil, light engine oil or lint free cloth. Do not use water, steam, kerosene or gasoline for cleaning. 5. Remove the sealant from the housing and cover surfaces. Use solvent to clean the mating surfaces. Fig. 3 6. Apply a bead of MOPAR Silicone Rubber Sealant, or equivalent, to the housing cover. Install the housing cover within 5 minutes after applying the sealant. 7. Install the cover and any identification tag. Tighten the cover bolts in a cries-cross pattern to 41 Nm (30 ft. lbs.) torque. 8. Refill the differential with MOPAR Hypoid Gear Lubricant, or equivalent, to bottom of the fill plug hole. 9. Install the fill hole plug and lower the vehicle. Tighten fill plug to 34 Nm (25 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Front Axle > Page 3620 Fluid - Differential: Service and Repair Rear Axle 1. Raise and support the vehicle. 2. Remove the lubricant fill hole plug from the differential housing cover. 3. Remove the differential housing cover and drain the lubricant from the housing. 4. Clean the housing cavity with a flushing oil, light engine oil, or lint free cloth. Do not use water, steam, kerosene, or gasoline for cleaning. 5. Remove the original sealant from the housing and cover surfaces. Fig. 8 6. Apply a bead of MOPAR Silicone Rubber Sealant. or equivalent. to the housing cover. Install the housing cover within 5 minutes after applying the sealant. 7. Install the cover and any identification tag. Tighten the cover bolts to 41 Nm (30 ft. lbs.) torque. 8. For Trac-LOC differentials, a quantity of MOPAR Trac-LOC lubricant (friction modifier), or equivalent, must be added after repair service or a lubricant change. 9. Fill differential with MOPAR Hypoid Gear Lubricant, or equivalent, to bottom of the fill plug hole. CAUTION: Overfilling the differential can result in lubricant foaming and overheating. 10. Install the fill hole plug and lower the vehicle. 11. Trac-LOC differential equipped vehicles should be road tested by making 10 to 12 slow figure-eight turns. This maneuver will pump the lubricant through the clutch discs to eliminate a possible chatter noise complaint. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Removal Pinion Bearing: Service and Repair Removal With Pinion Installed 1. Raise and support the vehicle. 2. Remove skid plate, if equipped. 3. Mark C/V driveshaft and axle shaft flanges for installation alignment reference. 4. Remove bolts holding the driveshafts to the axle shafts. 5. Separate the driveshafts from the axle shafts. 6. Mark the propeller shaft and pinion yoke for installation reference. 7. Remove the propeller shaft from the yoke. 8. Rotate the pinion gear three or four times. 9. Measure the amount of torque necessary to rotate the pinion gear with a (inch lbs.) dial-type torque wrench. Record the torque reading for installation reference. 10. Using a short piece of pipe and Holder 6958 to hold the pinion yoke, remove the pinion nut and washer. Fig. 10 11. Use Remover C-452 and Wrench C-3281 to remove the pinion yoke and pinion seal excluder. 12. Using a suitable pry tool, or a slide hammer mounted screw, remove the pinion seal. 13. Remove the front pinion bearing using a pair of suitable pick tools to pull the bearing straight off the pinion gear shaft. It may be necessary to lightly tap the end of the pinion gear with a rawhide or rubber mallet if the bearing becomes bound on the pinion shaft. 14. Remove the collapsible spacer. With Pinion Removed 1. Raise and support the vehicle. 2. Remove skid plate, if equipped. 3. Mark C/V driveshaft and axle shaft flanges for installation alignment reference. 4. Remove bolts holding the driveshafts to the axle shafts. 5. Separate the driveshafts from the axle shafts. 6. Mark the propeller shaft and pinion yoke for installation reference. 7. Remove the propeller shaft from the yoke. 8. Rotate the pinion gear three or four times. 9. Measure the amount of torque necessary to rotate the pinion gear with a (inch lbs.) dial-type torque wrench. Record the torque reading for installation reference. 10. Remove differential assembly from axle housing. 11. Using Holder 6958 to hold yoke and a short length of 1 inch pipe, remove the pinion yoke nut and washer. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Removal > Page 3625 Fig. 10 12. Using Remover C-452 and Wrench C-3281, remove the pinion yoke and pinion seal excluder from pinion shaft. Fig. 11 13. Remove the pinion gear from housing. Catch the pinion with your hand to prevent it from falling and being damaged. 14. Remove collapsible spacer from pinion shaft. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Removal > Page 3626 Pinion Bearing: Service and Repair Installation Fig. 12 1. Install a new collapsible preload spacer on pinion shaft. 2. If pinion gear was removed, install pinion gear in housing. 3. Install pinion front bearing, if necessary. Fig. 13 4. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer D-163 and Handle C-4171. 5. Inspect pinion seal excluder. Replace if necessary, and install pinion seal excluder on pinion yoke. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Removal > Page 3627 Fig. 14 6. Install yoke with Screw 8112, Cup 8109, and Holder 6958. 7. If the original pinion bearings are being used, install differential assembly and axle shafts, if necessary. NOTE: If new pinion bearings were installed, do not install the differential assembly and axle shafts until after the pinion bearing preload and rotating torque are set. 8. Install the yoke washer and a new nut on the pinion gear. Tighten the pinion nut until there is zero bearing end-play. 9. Tighten the nut to 271 Nm (200 ft. lbs.). CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque sequence will then have to be repeated. 10. Using yoke holder 6958, a short length of 1 inch pipe, and a torque wrench set at 474 Nm (350 ft. lbs.), crush collapsible spacer until bearing end play is taken up. NOTE: If more than 474 Nm (350 ft. lbs.) of torque is necessary to remove the bearing end play, the collapsible spacer is defective and must be replaced. Fig. 15 11. Slowly tighten the nut in 6.8 Nm (5 ft. lbs.) increments until the rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer. 12. Check rotating torque with an inch pound torque wrench. The torque necessary to rotate the pinion gear should be: - Original Bearings-The reading recorded during removal, plus an additional 0.56 Nm (5 inch lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Removal > Page 3628 - New Bearings-2 to 5 Nm (15 to 35 inch lbs.). 13. Install differential assembly and axle shafts, if necessary. 14. Align marks made previously on yoke and propeller shaft and install propeller shaft. 15. Align marks made previously on the driveshafts and axle shafts and install driveshafts. 16. Add gear lubricant, if necessary. 17. Install skid plate, if equipped. 18. Lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle Pinion Gear: Service and Repair Front Axle NOTE: The ring and pinion gears are serviced in a matched set. Do not replace the pinion gear without replacing the ring gear. REMOVAL 1. Remove differential from the axle housing. 2. Mark pinion yoke and propeller shaft for installation alignment. 3. Disconnect propeller shaft from pinion yoke. Using suitable wire, tie propeller shaft to underbody. 4. Using Holder 6958 to hold yoke and a short length of 1 inch pipe, remove the pinion yoke nut and washer. 5. Using Remover C-452 and Wrench C-3281, remove the pinion yoke and pinion seal excluder from pinion shaft. Fig. 24 6. Remove the pinion gear from housing. Catch the pinion with your hand to prevent it from falling and being damaged. 7. Using a suitable pry tool, or a slide hammer mounted screw, remove the pinion seal. 8. Remove oil slinger, if equipped, and front pinion bearing. Fig. 25 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle > Page 3633 9. Remove the front pinion bearing cup with Remover C-4345 and Handle C 4171. Fig. 26 10. Remove the rear bearing cup from housing. Use Remover 8132 and Handle C-4171. Fig. 27 11. Remove the collapsible preload spacer. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle > Page 3634 Fig. 28 12. Remove the rear bearing from the pinion with Puller/Press C-293-PA and Adapters C-293-40. Place 4 adapter blocks so they do not damage the bearing cage. 13. Remove the depth shims from the pinion gear shaft. Record the thickness of the depth shims. INSTALLATION 1. Apply MOPAR Door Ease, or equivalent, stick lubricant to outside surface of bearing cup. Fig. 29 2. Install the pinion rear bearing cup with Installer D-146 and Driver Handle C-4171. Ensure cup is correctly seated. 3. Apply MOPAR Door Ease, or equivalent, stick lubricant to outside surface of bearing cup. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle > Page 3635 Fig. 30 4. Install the pinion front bearing cup with Installer D-130 and Handle C-4171. 5. Install pinion front bearing, and oil slinger, if equipped. Fig. 31 6. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer D-163 and Handle C-171. NOTE: Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to achieve proper ring and pinion gear mesh. If the factory installed ring and pinion gears are reused, the pinion depth shim should not require replacement. If required, refer to Pinion Gear Depth to select the proper thickness shim before installing rear pinion bearing. 7. Place the proper thickness depth shim on the pinion gear. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle > Page 3636 Fig. 32 8. Install the rear bearing and slinger, if equipped, on the pinion gear with Installer W-262. Fig. 33 9. Install a new collapsible preload spacer on pinion shaft and install pinion gear in housing. 10. Install pinion gear in housing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle > Page 3637 Fig. 34 11. Install yoke with Installer Screw 8112, Cup 8109, and holder 6958. 12. Install the yoke washer and a new nut on the pinion gear and tighten the pinion nut until there is zero bearing end-play. 13. Tighten the nut to 271 Nm (200 ft. lbs.). CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque sequence will then have to be repeated. 14. Using yoke holder 6958, a short length of 1 inch pipe, and a torque wrench set at 474 Nm (350 ft. lbs.), crush collapsible spacer until bearing end play is taken up. NOTE: If the spacer requires more than 474 Nm (350 ft. lbs.) torque to crush, the collapsible spacer is defective and must be replaced. Fig. 35 15. Slowly tighten the nut in 6.8 Nm (5 ft. lbs.) increments until the rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer. 16. Check bearing rotating torque with an inch pound torque wrench. The torque necessary to rotate the pinion gear should be: - Original Bearings - 1 to 3 Nm (10 to 20 inch lbs.). - New Bearings - 2 to 5 Nm (15 to 35 inch lbs.). 17. Install differential in housing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle > Page 3638 Pinion Gear: Service and Repair Rear Axle NOTE: The ring and pinion gears are serviced in a matched set. Do not replace the pinion gear without replacing the ring gear. REMOVAL 1. Remove differential from the axle housing. 2. Mark pinion yoke and propeller shaft for installation alignment. 3. Disconnect propeller shaft from pinion yoke. Using suitable wire, tie propeller shaft to underbody. 4. Using Yoke Holder 6719 to hold yoke and remove the pinion yoke nut and washer. Fig. 26 5. Using Remover C-452, remove the pinion yoke from pinion shaft. 6. Partially install pinion nut onto pinion to protect the threads. Fig. 27 7. Remove the pinion gear from housing. Catch the pinion with your hand to prevent it from falling and being damaged. 8. Remove the pinion shaft seal with suitable pry tool or slide-hammer mounted screw. 9. Remove oil slinger, if equipped, and front pinion bearing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle > Page 3639 Fig. 28 10. Remove the front pinion bearing cup with: - Remover C-4345 and Handle C-4171 for the 8 1/4 axles. - Bearing Removal Tool Set 6310 and Adapter Foot 6310-9 for the 9 1/4 axles. Fig. 29 11. Remove the rear bearing cup from housing. Use: - Remover C-4307 and Handle C-4171 for the 8 1/4 axle. - Remover C-4309 and Handle C-4171 for the 9 1/4 axle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle > Page 3640 Fig. 30 12. Remove the collapsible preload spacer. Fig. 31 13. Remove the rear bearing from the pinion with: - Puller/Press C-293-PA and Adapters C-293-47 for the 8 1/4 axle. - Puller/Press C-293-PA and Adapters C-293-37 for the 9 1/4 axle. Place 4 adapter blocks so they do not damage the bearing cage. 14. Remove the depth shims from the pinion gear shaft. Record the thickness of the depth shims. INSTALLATION 1. Apply MOPAR Door Ease, or equivalent, stick lubricant to outside surface of bearing cup. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle > Page 3641 Fig. 32 2. Install the pinion rear bearing cup with: - Installer C-4308 and Driver Handle C-4171 for the 8 1/4 axle. - Installer C-4310 and Driver Handle C-4171 for the 9 1/4 axle. 2. Ensure cup is correctly seated. 3. Apply MOPAR Door Ease, or equivalent, stick lubricant to outside surface of bearing cup. Fig. 33 4. Install the pinion front bearing cup with: - Installer D-130 and Handle C-4171 for the 8 1/4 axle. - Installer D-129 and Handle C-4171 for the 9 1/4 axle. 5. Install pinion front bearing, and oil slinger, if equipped. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle > Page 3642 Fig. 34 6. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with: - Installer C-4076-B and Handle C-4736-1 for the 8 1/4 axle. - Installer C-3860-A and Handle C-4171 for the 9 1/4 axle. NOTE: Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to achieve proper ring and pinion gear mesh. If the factory installed ring and pinion gears are reused, the pinion depth shim should not require replacement. If required, refer to Pinion Gear Depth to select the proper thickness shim before installing rear pinion bearing. 7. Place the proper thickness depth shim on the pinion gear. Fig. 35 8. Install the rear bearing and slinger, if equipped, on the pinion gear with: - Installer 6448 for the 8 1/4 axle. - Installer C-3095 for the 9 1/4 axle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle > Page 3643 Fig. 36 9. Install a new collapsible preload spacer on pinion shaft and install pinion gear in housing. 10. Install pinion gear in housing. 11. Install yoke with Installer C-3718 and Yoke Holder 6719. 12. Install the yoke washer and a new nut on the pinion gear and tighten the pinion nut until there is zero bearing end-play. It will not be possible at this point to achieve zero bearing end-play if a new collapsible spacer was installed. 13. Tighten the nut to 285 Nm (210 ft. lbs.). CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque sequence will then have to be repeated. 14. Using Yoke Holder 6719, crush collapsible spacer until bearing end play is taken up. Fig. 37 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. 16. Check bearing rotating torque with an inch pound torque wrench. The torque necessary to rotate the pinion gear should be: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Front Axle > Page 3644 - Original Bearings - 1 to 3 Nm (10 to 20 inch lbs.). - New Bearings - 2 to 5 Nm (15 to 35 inch lbs.). 17. Install propeller shaft. 18. Install differential in housing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle Ring Gear: Service and Repair Front Axle The ring and pinion gears are service in a matched set. Do not replace the ring gear without replacing the pinion gear. REMOVAL 1. Remove differential from axle housing. Fig. 22 2. Place differential case in a suitable vise with soft metal jaw protectors. 3. Remove bolts holding ring gear to differential case. 4. Using a soft hammer, drive ring gear from differential case. INSTALLATION CAUTION: Do not reuse the bolts that held the ring gear to the differential case. The bolts can fracture causing extensive damage. 1. Invert the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. 2. Invert the differential case in the vise. Fig. 23 3. Install new ring gear bolts and alternately tighten to 95-122 Nm (70-90 ft. lbs.) torque. 4. Install differential in axle housing and verify Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle > Page 3649 Ring Gear: Service and Repair Rear Axle NOTE: The ring and pinion gears are serviced in a matched set. Do not replace the ring gear without replacing the pinion gear. REMOVAL 1. Remove differential from axle housing. Fig. 24 2. Place differential case in a suitable vise with soft metal jaw protectors. 3. Remove bolts holding ring gear to differential case. 4. Using a soft hammer, drive ring gear from differential case. 5. Use a brass drift and slowly tap the exciter ring from the differential case. INSTALLATION CAUTION: Do not reuse the bolts that held the ring gear to the differential case. The bolts can fracture causing extensive damage. 1. Invert the differential case. 2. Position exciter ring on differential case. 3. Using a brass drift, slowly and evenly tap the exciter ring into position. 4. Position ring gear on the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. 5. Invert the differential case in the vise. Fig. 25 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Front Axle > Page 3650 6. Install new ring gear bolts and alternately tighten to: - 102 Nm (75 ft. lbs.) torque for 8 1/4 axles. - 157 Nm (115 ft. lbs.) torque for 9 1/4 axles. 7. Install differential in axle housing and verify Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Pinion Seal Replacement Seals and Gaskets: Service and Repair Pinion Seal Replacement REMOVAL 1. Raise and support the vehicle. 2. Scribe a mark on the universal joint, pinion yoke, and pinion shaft for reference. 3. Disconnect the propeller shaft from the pinion yoke. Secure the propeller shaft in an upright position to prevent damage to the rear universal joint. 4. Remove the wheel and tire assemblies. 5. Remove the brake drums to prevent any drag. The drag may cause a false bearing rotating torque measurement. 6. Rotate the pinion yoke three or four times. 7. Measure the amount of torque necessary to rotate the pinion gear with a (inch lbs.) dial-type torque wrench. Record the torque reading for installation reference. 8. Hold the yoke with Wrench 6719. Remove the pinion shaft nut and washer. Fig. 14 9. Remove the yoke with Remover C-452. 10. Remove the pinion shaft seal with suitable pry tool or slide-hammer mounted screw. INSTALLATION 1. Clean the seal contact surface in the housing bore. 2. Examine the splines on the pinion shaft for burrs or wear. Remove any burrs and clean the shaft. 3. Inspect pinion yoke for cracks, worn splines and worn seal contact surface. Replace yoke if necessary. NOTE: The outer perimeter of the seal is pre-coated with a special sealant. An additional application of sealant is not required. 4. Apply a light coating of gear lubricant on the lip of pinion seal. Fig. 15 5. Install the new pinion shaft seal with: - 8 1/4 axle: Installer C-4076-B and Handle C-4735-1. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Pinion Seal Replacement > Page 3655 - 9 1/4 axle: Installer C-3860-A and Handle C-4171. NOTE: The seal is correctly installed when the seal flange contacts the face of the differential housing flange. 6. Position the pinion yoke on the end of the shaft with the reference marks aligned. 7. Seat yoke on pinion shaft with Installer C-3718 and Wrench 6719. 8. Remove the tools and install the pinion yoke washer. The convex side of the washer must face outward. CAUTION: Do not exceed the minimum tightening torque when installing the pinion yoke retaining nut at this point. Damage to collapsible spacer or bearings may result. Fig. 16 9. Hold pinion yoke with Yoke Holder 6719 and tighten shaft nut to 285 Nm (210 ft. lbs.). Rotate pinion shaft several revolutions to ensure the bearing rollers are seated. Fig. 17 10. Rotate the pinion shaft using an (inch lbs.) torque wrench. Rotating torque should be equal to the reading recorded during removal, plus an additional 0.56 Nm (5 inch lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Pinion Seal Replacement > Page 3656 CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload torque. If preload torque is exceeded a new collapsible spacer must be installed. The torque sequence will then have to be repeated. 11. If the rotating torque is low, use Yoke Holder 6719 to hold the pinion yoke and tighten the pinion shaft 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. 12. The seal replacement is unacceptable if the final pinion nut torque is less than 285 Nm (210 ft. lbs.). 13. Install the propeller shaft with the installation reference marks aligned. 14. Tighten the universal joint yoke clamp screws to 19 Nm (14 ft. lbs.). 15. Install the brake drums. 16. Install wheel and tire assemblies and lower the vehicle. 17. Check the differential housing lubricant level. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Pinion Seal Replacement > Page 3657 Seals and Gaskets: Service and Repair Pinion Seal, Front Differential REMOVAL 1. Raise and support the vehicle. 2. Remove skid plate, if equipped. 3. Mark the C/V driveshaft and axle flanges for installation alignment reference. 4. Remove the bolts holding the driveshafts to the axle shafts. 5. Separate the driveshaft from the axle shafts. 6. Mark the propeller shaft and pinion yoke for installation alignment reference. 7. Remove the propeller shaft from the yoke. 8. Rotate the pinion gear three or four times. 9. Measure the amount of torque necessary to rotate the pinion gear with a (inch lbs.) dial-type torque wrench. Record the torque reading for installation reference. 10. Using Yoke Holder 6958, remove the pinion nut and washer. Fig. 6 11. Use Remover C-452 and Wrench C-3281 to remove the pinion yoke. 12. Remove the pinion seal excluder from the pinion yoke. 13. Using a suitable pry tool, or a slide hammer mounted screw, remove the pinion seal. INSTALLATION 1. Apply a light coating of gear lubricant on the lip of pinion seal. Fig. 7 2. Install seal with Installer D-163 and Handle C-4171. 3. Install new pinion seal excluder to pinion yoke. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Pinion Seal Replacement > Page 3658 Fig. 8 4. Install yoke on the pinion gear with Screw 8112, Cup 8109, and Holder 6958. CAUTION: Do not exceed the minimum tightening torque when installing the pinion yoke at this point. Damage to the collapsible spacer or bearings may result. 5. Install the yoke washer and a new nut on the pinion gear and tighten the pinion nut until there is zero bearing end-play. 6. Tighten the nut to 271 Nm (200 ft. lbs.). CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque sequence will then have to be repeated. Fig. 9 7. Rotate the pinion shaft using a (inch lbs.) torque wrench. Rotating torque should be equal to the reading recorded during removal plus an additional 0.56 Nm (5 inch lbs.). 8. If the rotating torque is low, use Holder 6958 to hold the pinion yoke, and tighten the pinion shaft nut in 6.8 Nm (5 ft. lbs.) increments until the proper rotating torque is achieved. CAUTION: If the maximum tightening torque is reached prior to reaching the required rotating torque, the collapsible spacer may have been damaged. Replace the collapsible spacer. 9. Align the installation reference marks on the propeller shaft and yoke and install the propeller shaft. 10. Add gear lubricant to the differential housing, if necessary. 11. Align the reference marks on the driveshaft and axle shaft flanges and install bolts to hold the driveshafts to the axle shafts. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Pinion Seal Replacement > Page 3659 12. Install skid plate, if equipped. 13. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications Axle Shaft: Specifications Bolts, Axle Flange 65 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 3665 Axle Shaft: Description and Operation Fig. 1 The two constant velocity (C/V) drive shafts are identical and interchangeable. They are comprised of three major components: An inner, tripod C/V joint - A short, solid interconnecting shaft - An outer, Rzeppa C/V joint with stub shaft The inner tripod joints are attached to the axle shaft flanges. The outer joint is splined and mates with the hub bearing on the knuckle. The lubricant amounts included with replacement rubber boots are different for inner and outer C/V joints. Apply only the specified lubricant amount to each C/V joint. CAUTION: Proper C/V joint boot sealing is critical for retaining the special lubricant. Prevent foreign material from entering and contaminating the C/V joints. Mishandling a C/V drive shaft can cause a boot to be punctured or damage within the joints. Always support both ends of the C/V drive shaft during removal and installation to avoid damage. When replacing C/V drive shaft components, ensure that only exact replacements parts are installed. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Testing and Inspection > Clunking Noise During Acceleration Axle Shaft: Testing and Inspection Clunking Noise During Acceleration This noise may be a result of one of the following conditions: A torn seal boot on the inner or outer joint of the driveshaft assembly which has allowed the C/V joint to become damaged. - A loose or missing clamp on the inner or outer joint of the driveshaft assembly which has allowed the C/V joint to become damaged. - A damaged or worn driveshaft C/V joint. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Testing and Inspection > Clunking Noise During Acceleration > Page 3668 Axle Shaft: Testing and Inspection Noise and/or Vibration In Turns A clicking noise and/or a vibration in turns could be caused by one of the following conditions: Damaged outer C/V or inner tripod joint seal boot or seal boot clamps. This will result in the loss and/or contamination of the joint grease, resulting in inadequate lubrication of the joint. - Noise may also be caused by another component of the vehicle coming in contact with the driveshafts. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Testing and Inspection > Clunking Noise During Acceleration > Page 3669 Axle Shaft: Testing and Inspection Shudder or Vibration During Acceleration This problem could be a result of: A worn or damaged driveshaft inner tripod joint. - A sticking tripod joint spider assembly (inner tripod joint only). - Improper wheel alignment. Refer to Steering and Suspension, for alignment checking and setting procedures and specifications. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Testing and Inspection > Clunking Noise During Acceleration > Page 3670 Axle Shaft: Testing and Inspection Vehicle Inspection 1. Check for grease in the vicinity of the inboard tripod joint and outboard C/V joint; this is a sign of inner or outer joint seal boot or seal boot clamp damage. 2. A light film of grease may appear on the right inner tripod joint seal boot; this is considered normal and should not require replacement of the seal boot. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Testing and Inspection > Clunking Noise During Acceleration > Page 3671 Axle Shaft: Testing and Inspection Vibration at Highway Speeds This problem could be a result of: Foreign material (mud, etc.) packed on the backside of the wheel(s). - Out of balance front tires or wheels. Refer to Steering and Suspension; Wheels Tires And Alignment, for the required balancing procedure. - Improper tire and/or wheel runout. Refer to Steering and Suspension; Wheels Tires And Alignment, for the required runout checking procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Constant Velocity Type Axle Shaft Assembly Axle Shaft: Service and Repair Constant Velocity Type Axle Shaft Assembly Removal and Installation REMOVAL Fig. 2 1. Remove the cotter pin, nut lock, and spring washer from the stub shaft. Fig. 3 2. Loosen the lug nuts and hub nut while the vehicle is on the surface with the brakes applied. 3. Raise the vehicle. 4. Remove the skid plate, if equipped. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Constant Velocity Type Axle Shaft Assembly > Page 3674 Fig. 4 5. Remove the hub nut and washer from the stub shaft. 6. Remove the wheel and tire. 7. Loosen the bolts that attach the inner C/V joint to the axle shaft. 8. Remove the brake caliper and rotor. Refer to Brakes and Traction Control, for proper procedures. 9. Remove the ABS wheel speed sensor, if equipped. Refer to Brakes and Traction Control for proper procedures. 10. Remove the bolts holding the hub bearing to the knuckle. 11. Remove hub bearing from axle driveshaft and steering knuckle. 12. Support the drive shaft at the C/V joint housings. 13. Remove bolts that attach the inner C/V joint to the axle shaft. 14. Remove the driveshaft from the vehicle. INSTALLATION 1. Insert the CV drive shaft stub into the hub bearing bore of the steering knuckle. 2. Attach the inner joint flange to the axle shaft flange. Tighten the bolts to 90 Nm (65 ft. lbs.) torque. 3. Clean hub bearing bore, axle driveshaft splines, and hub bearing mating surface of all foreign materials. Apply light coating of grease to all mating surfaces. 4. Install the hub bearing to the axle driveshaft and the steering knuckle. 5. Install the bolts to hold the hub bearing to the steering knuckle. Tighten bolts to 166 Nm (123 ft. lbs.). 6. Clean all foreign material from the stub shaft threads. Install the hub nut and washer. 7. Install the ABS wheel speed sensor, if equipped. Refer to Brakes and Traction Control, for proper procedures. 8. Install the brake caliper and rotor. Refer to Brakes and Traction Control, for proper procedures. 9. Apply the brakes and tighten hub nut to 244 Nm (180 ft. lbs.) torque. Fig. 5 10. Install the spring washer, nut lock and cotter pin on the stub shaft. 11. Install the skid plate, if equipped. 12. Install the wheel and tire. Inner C/V Joint DISASSEMBLY 1. Remove the axle driveshaft. 2. Place the inner C/V joint housing in a vise. 3. Remove the inner boot retaining clamps. Pull the inner boot back onto the interconnecting shaft. Discard the retaining clamps. 4. Pull the tripod and shaft straight out from the inner C/V joint housing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Constant Velocity Type Axle Shaft Assembly > Page 3675 Fig. 8 Fig. 9 5. Remove the snap retaining ring from the groove behind the tripod. Slide the tripod toward the center of the shaft. Remove the C-clip on the outer end of the shaft. 6. Remove the tripod from the shaft. Replace the boot, if necessary. 7. Remove the lubricant from the interior of the housing and from the tripod. 8. Inspect the needle bearing raceways in the housing and tripod components for excessive wear and damage. Replace the tripod as a unit only if necessary. ASSEMBLY 1. Slide the boot down enough for work access. 2. Install the snap ring past the ring groove (toward the center of the shaft). Slide the tripod onto the end of the interconnecting shaft. Be sure the chamfered end of the tripod is adjacent to the C-clip retaining ring groove. 3. Install the C-clip in the groove. Slide the tripod out against the clip. Install the snap ring in the inner groove. Be sure the snap ring and C-clip are seated. 4. Apply the required quantity of lubricant to the housing and boot. Coat the interior of the joint housing and the tripod. 5. Insert and seat the tripod and shaft in the housing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Constant Velocity Type Axle Shaft Assembly > Page 3676 Fig. 10 6. Position the large-diameter end of the inner C/V joint boot over the edge of the housing. Insert the lip of the boot into the locating groove at the edge of the housing. 7. Insert the small lip into the locating groove in the interconnecting shaft. Fig. 6 8. Retain the small-diameter of the boot on the shaft with a ladder-type clamp in the boot groove. Verify that the boot and lip are properly positioned on the intermediate shaft. Position the clamp locating tabs in the slots and tighten the clamp. Fig. 11 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Constant Velocity Type Axle Shaft Assembly > Page 3677 9. Compress the clamp bridge with Remover/Installer C-4124. Squeeze the tool handles to complete the tightening of the clamp. Care must be exercised when using the tool to avoid cutting through the clamp bridge or damaging the boot. 10. Position the large-diameter end of the boot on the C/V joint housing. 11. After the inner joint boot small clamp is installed, the inboard hub must be set to a service build length. a. Compress the inner hub down the connector shaft. b. Use a small blunt drift between the large end and the boot seal to relieve the pressure. c. The distance edge of the lip to the edge of the flange should be 181.00 mm (7.13 inch). This will eliminate excess air that can cause a ballooning affect and possibly cause damage to the boot. 12. Verify that the boot is not twisted and that it is correctly positioned on the housing. 13. Install the large ladder clamp on the boot and secure as done with the small ladder clamp. Outer C/V Joint If the outer C/V joint is excessively worn, replace the entire C/V joint and boot. DISASSEMBLY 1. Remove retaining clamps from the outer C/V joint and discard. Slide the boot off the outer joint and down the shaft. Fig. 12 2. Remove the lubricant to expose the outer C/V joint components. 3. Clamp the shaft in a vise (with soft jaws). Support the outer C/V joint. 4. Use snap ring pliers to release the clip from the groove. Fig. 13 5. Slide the outer C/V joint from the shaft. 6. Remove the slinger, if damaged, from the outer C/V joint. Use a brass drift and a hammer. Tap slinger ring off C/V joint and discard. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Constant Velocity Type Axle Shaft Assembly > Page 3678 Fig. 14 7. Remove the old lubricant. Apply installation alignment marks on the bearing hub, bearing cage and housing with dabs of paint. 8. Clamp the outer C/V joint in a vertical position. Place the stub shaft in a softjawed vise. 9. Press down on one side of the bearing cage/hub to tilt the cage. This will provide access to a ball at the opposite side of the cage. If the C/V joint is tight, use a hammer and brass drift to loosen the bearing hub. Do not contact the bearing cage with the drift. Fig. 15 10. Remove the ball from the bearing cage. If necessary, a small pry bar can be used to pry the ball loose from the cage. 11. Repeat the step above until all six balls are removed from the bearing cage. Fig. 16 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Constant Velocity Type Axle Shaft Assembly > Page 3679 12. Tilt the bearing cage and hub to a vertical position. Remove the cage from the housing. Pull cage upward and away from the housing. Fig. 17 13. Turn the bearing hub 90° from the bearing cage. Align one pair of the hub lands with the cage windows. Raise and insert one of the lands into the adjacent cage window. Remove the bearing hub by rolling it out of the cage. ASSEMBLY 1. Lightly apply lubricating oil to all the outer C/V joint components before assembling them. 2. Align the bearing hub, cage and housing according to the alignment reference marks. Fig. 18 Fig. 19 3. Insert one of the bearing hub lands into a bearing cage window. Roll the hub into the cage. Rotate the bearing hub 90° to complete the installation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Constant Velocity Type Axle Shaft Assembly > Page 3680 Fig. 20 Fig. 21 4. Insert bearing cage/hub into the housing. Rotate the cage/hub 90° to complete the installation. 5. Apply the lubricant included with the replacement boot to the ball raceways. Spread the lubricant equally between all the raceways. One packet of lubricant is sufficient to lubricate the complete C/V joint. Fig. 22 6. Tilt the bearing hub and cage and install the balls in the raceways. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Constant Velocity Type Axle Shaft Assembly > Page 3681 Fig. 23 7. Apply a small amount of lubricant to inner diameter of slinger. Place slinger squarely on the outer C/V joint. Use installer tool L-4518-1 from tool set L-4518 and hammer slinger onto joint until it seats. CAUTION: Prevent damage to the slinger after installation or a when a replacement outer ON joint is installed. 8. Position the small-diameter end of the replacement boot on the interconnecting shaft. Retain the boot with a replacement clamp. 9. Apply the required amount of lubricant to the outer C/V joint and boot. Fig. 24 10. Align the shaft splines to the outer C/V joint splines. Push the outer C/V joint until the snap ring seats in the groove. 11. Ensure that the snap ring is properly seated in the housing. Pull the outer C/V joint from the interconnecting shaft to test. 12. Place the large-diameter end of the replacement boot over the edge of the C/V joint housing. Ensure that the boot is not twisted. 13. Retain the boot on the housing with a replacement retaining clamps. C/V Joints Inspect the lubricant for contamination. Inspect the C/V joint components for defects according to the following instructions. 1. Clean all the components with an appropriate solvent and dry them with compressed air. 2. Inspect the ball raceways in the housing for excessive wear and scoring. 3. Examine the stub shaft splines and threads for damage. 4. Inspect the balls for pitting, cracks, scoring and excessive wear. A dull exterior surface is normal. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Constant Velocity Type Axle Shaft Assembly > Page 3682 5. Inspect the bearing cage for wear, grooves, ripples, cracks and chipping. Fig. 25 6. Inspect the bearing hub for excessive wear and scoring on ball raceways. Polished contact surface areas on the raceways and on the bearing cage spheres are normal. If the joints cause a noise or a vibration, replace them. C/V Joint Boots Look for lubricant around the exterior of a boot. When a C/V drive shaft is removed from the vehicle for service, the boot should be properly cleaned. Inspect for cracks, tears and scuffed areas on the surfaces. If any of these conditions exist, boot replacement is recommended. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Constant Velocity Type Axle Shaft Assembly > Page 3683 Axle Shaft: Service and Repair Conventional Fixed/Floating Axle Shaft Front Axle REMOVAL 1. Raise and support vehicle. Ensure that the transmission is in neutral. 2. Remove C/V driveshaft from vehicle. 3. Remove shock absorber, if removing the right axle shaft. Refer to Steering and Suspension, for proper procedures. 4. Remove the skid plate, if equipped, if removing the left axle shaft. 5. Clean all foreign material from housing cover area. 6. Loosen housing cover bolts. Drain lubricant from the housing. Remove housing cover. 7. Remove E-clip retaining axle shaft into differential side gears. 8. Remove axle shaft. Use care to prevent damage to axle shaft bearing and seal, which will remain in axle shaft tube. 9. Inspect axle shaft seal for leakage or damage. 10. Inspect roller bearing contact surface on axle shaft for signs of brinelling, galling and pitting. If any of these conditions exist, the axle shaft and/or bearing and seal must be replaced. 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 E-clip lock in end of axle shaft. 3. Install cover and add fluid. 4. Install shock absorber, if necessary. Refer to Steering and Suspension, for proper procedures. 5. Install skid plate, if necessary. 6. Install C/V driveshaft. 7. Lower vehicle. Rear Axle REMOVAL 1. Raise and support vehicle. Ensure that the transmission is in neutral. 2. Remove wheel and tire assembly. 3. Remove brake drum. Refer to Brakes and Traction Control for proper procedure. 4. Clean all foreign material from housing cover area. 5. Loosen housing cover bolts. Drain lubricant from the housing and axle shaft tubes. Remove housing cover. Fig. 9 6. Rotate differential case so that pinion mate gear shaft lock screw is accessible. Remove lock screw and pinion mate gear shaft from differential case. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Constant Velocity Type Axle Shaft Assembly > Page 3684 Fig. 10 7. Push axle shaft inward and remove axle shaft C-clip lock from the axle shaft. 8. Remove axle shaft. Use care to prevent damage to axle shaft bearing and seal, which will remain in axle shaft tube. 9. Inspect axle shaft seal for leakage or damage. 10. Inspect roller bearing contact surface on axle shaft for signs of brinelling, galling and pitting. If any of these conditions exist, the axle shaft and/or bearing and seal must be replaced. 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-clip lock in end of axle shaft. Push axle shaft outward to seat C-clip lock in side gear. 3. Insert pinion mate shaft into differential case and through thrust washers and pinion gears. 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.) torque. 5. Install cover and add fluid. Refer to Lubricant Change. 6. Install brake drum. Refer to Brakes and Traction Control for proper procedures. 7. Install wheel and tire. 8. Lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 3685 Axle Shaft: Tools and Equipment Tool Set L-4518 Remover/Installer C-4124 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Cleaning and Inspection Constant Velocity Joint: Service and Repair Cleaning and Inspection Refer to Axle Shaft Assembly, Constant Velocity Type, Service and Repair for procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Cleaning and Inspection > Page 3690 Constant Velocity Joint: Service and Repair Disassembly and Assembly Refer to Axle Shaft Assembly, Constant Velocity Type, Service and Repair for procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair Constant Velocity Joint Boot: Service and Repair REMOVAL 1. Remove axle driveshaft from vehicle. 2. Remove outer C/V joint. Fig. 6 3. Remove outer C/V joint small clamp and remove boot. 4. Remove inner C/V joint boot clamps and remove boot. INSTALLATION The lubricant amounts included with replacement boots are different for inner and outer C/V joints. Apply only the specified lubricant amount to each C/V joint. 1. Clean the C/V joints and shaft of all old grease and foreign matter. 2. Slide the inner C/V joint boot up the shaft and insert the lip located within the small-diameter end of the boot into the shaft groove. 3. Retain the small-diameter of the boot on the shaft with a ladder-type clamp in the boot groove. Verify that the boot and lip are properly positioned on the intermediate shaft. Position the clamp locating tabs in the slots and tighten the clamp. Fig. 7 4. Compress the clamp bridge with Remover/Installer C-4124. Squeeze the tool handles to complete the tightening of the clamp. Care must be exercised when using the tool to avoid cutting through the clamp bridge or damaging the hoot. 5. Position the large-diameter end of the boot on the C/V joint housing. 6. After the inner joint boot small clamp is installed, the inboard hub must be set to a service build length. a. Compress the inner hub down the connector shaft. b. Use a small blunt drift between the large end and the boot seal to relieve the pressure. c. The distance edge of the lip to the edge of the flange should be 181.00 mm (7.13 inch). This will eliminate excess air that can cause a ballooning affect and possibly cause damage to the boot. 7. Verify that the boot is not twisted and that it is correctly positioned on the housing. 8. Install the large ladder clamp on the boot and secure as done with the small ladder clamps. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Page 3694 9. Slide the outer C/V joint boot small clamp onto shaft. 10. Slide outer C/V joint boot onto shaft and into position on shaft. 11. Install small clamp to boot as done above. 12. Install large boot clamp over outer C/V joint. 13. Install outer C/V joint to shaft. 14. Install large boot clamp to boot and C/V joint. 15. Install the C/V driveshaft. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Front Axle Seals and Gaskets: Service and Repair Front Axle REMOVAL 1. Remove the axle shaft. 2. Remove the axle shaft seal from the end of the axle shaft tube with a small pry bar. 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 C-4660 and Cup 8150. 4. Inspect the axle shaft tube bore for roughness and burrs. Remove as necessary. INSTALLATION Do not install the original axle shaft seal. Always install a new seal. 1. Wipe the axle shaft tube bore clean. 2. Install axle shaft bearing with Installer 6436 and Handle C-4171. Ensure that the part number on the bearing is against the installer. Fig. 16 3. Install the new axle shaft seal with Installer 6437 and Handle C-4171. 4. Install the axle shaft. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Front Axle > Page 3699 Seals and Gaskets: Service and Repair Rear Axle REMOVAL 1. Remove axle shaft. Fig. 11 2. Remove axle shaft seal from the end of the axle tube with a small pry bar. NOTE: The seal and bearing can be removed at the same time with the bearing removal tool. Fig. 12 3. Remove the axle shaft bearing from the axle tube with Bearing Removal Tool Set 6310, using Adapter Foot 6310-9. INSTALLATION NOTE: Do not install the original axle shaft seal. Always install a new seal. 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Front Axle > Page 3700 Fig. 13 2. Install the axle shaft bearing with Installer C-4198 and Handle C-4171. Ensure that the bearing part number is against the installer. Verify that 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Front Hub Seals - Grease Purge Explanation Wheel Bearing: Technical Service Bulletins Front Hub Seals - Grease Purge Explanation NUMBER: 02-06-99 Rev. A GROUP: Suspension DATE: Dec. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-06-99, DATED JUNE 11, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF 4X2 MODELS AND ADDITIONAL MODEL YEARS. SUBJECT: Front Wheel Bearing Grease Is Evident On The Bearing Seal Area. MODELS: 1997 - **2000** (AN) Dakota 1994 - **2000** (BR/BE) Ram Truck 1998 - **2000** (DN) Durango DISCUSSION: Front wheel bearings may be incorrectly diagnosed as faulty due to the evidence of wheel bearing grease on the bearing seal areas. This grease purge is a normal design condition. The factory fill of the bearings includes a slightly greater amount of grease than is required for the bearing lifetime lubricant. A portion of the grease purges through the self-venting seal in the initial few thousand miles to form an additional barrier in the area of the seal and the stamped slinger. This barrier aids in the prevention of contaminants passing through the seal and into the bearing. Do not remove or clean the purged grease as part of normal maintenance due to the fact that it provides additional protection and once removed, damage to the seal and bearing could result. NOTE: UNDER NORMAL CONDITIONS, THERE MAY BE A SPLATTERING OF GREASE RADIALLY OUTWARD ON THE STEERING KNUCKLE FROM THE GREASE BARRIER AREA THAT CAN BE AS THICK AS 4 MM (0.125 IN.). Front wheel bearings should be replaced only if: ^ The seal shows visible damage ^ The bearing endplay is greater than 0.13 mm (0.005 in.) ^ The bearing was operated without the proper clamping force from the spindle nut ^ The bearing has a rough, sticky feel when rotated POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Page 3705 Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Page 3706 Wheel Bearing: Service Precautions Use only a grease that is recommended for wheel bearing applications. Use of the improper grease can cause bearing damage. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Refer to Axle Shaft, Conventional Fixed/Floating, Axle Shaft Seal for procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3709 Wheel Bearing: Service and Repair Rear Refer to Axle Shaft, Conventional Fixed/Floating, Axle Shaft Seal for procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Nut, Axle 180 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Specifications Center Support: Specifications TIGHTENING SPECIFICATION Bolts, Center Bearing .......................................................................................................................... ................................................. 68 Nm (50 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Specifications > Page 3718 Center Support: Service and Repair REMOVAL 1. Remove rear propeller shaft. 2. Remove slip joint boot clamp and separate the two half-shafts. 3. Use hammer and punch to tap slinger away from shaft to provide room for bearing splitter. 4. Position Bearing Splitter Tool 1130 between slinger and shaft. CAUTION: Do not damage shaft spline during removal of center bearing. 5. Set shaft in press and press bearing off the shaft. INSTALLATION 1. Install new slinger on shaft and drive into position with appropriate installer tool. 2. Install new center bearing on shaft with Bearing Installer Tool 6052. Drive on shaft with hammer until bearing is seated. 3. Clean shaft splines and apply a coat of multi-purpose grease. 4. Align master splines and slide front and rear half-shafts together. Reposition slip yoke boot and install new clamp. 5. Install propeller shaft in vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service Precautions Drive/Propeller Shaft: Service Precautions 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. Fig. 3 Also make alignment reference marks 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. CAUTION: It is very important to protect the external machined surface of the slip yoke from damage during and after propeller shaft removal. If the yoke is damaged, the transmission extension seal may be damaged and therefore cause a leak. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > General Information Drive/Propeller Shaft: Description and Operation General Information Fig. 1 The propeller shaft transmits power from one point to another in a smooth and continuous action. The shaft is designed to send torque through an angle from the transmission (transfer case on 4WD vehicles) to the axle. 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. This means the propeller shaft must be able to contract, expand and change operating angles when going over various road surfaces. This is accomplished through universal joints, which permit the propeller shaft to operate at different angles. The slip joints (or yokes) permit contraction or expansion. Tubular propeller shafts are balanced by the manufacturer with weights spot welded to the tube. The propeller shaft is designed and built with the yoke lugs in line with each other. This is called phasing. This design produces the smoothest running condition. An out of phase shaft can cause a vibration. Before undercoating a vehicle, the propeller shaft and the U-joints should be removed if possible. If removal is not possible, make sure that the propeller shaft and U-joints are fully covered. This will prevent the undercoating from causing an out of balance condition and vibration. CAUTION: Use exact replacement parts for attaching the propeller shafts. This will ensure safe operation. The specified torque must always be applied when tightening the fasteners. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > General Information > Page 3724 Drive/Propeller Shaft: Description and Operation Center Bearings Vehicles equipped with a two-piece propeller shaft uses a rubber insulated center bearing. The bearing is used to support the shafts where they are joined together. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > General Information > Page 3725 Drive/Propeller Shaft: Description and Operation Lubrication The slip yoke on the front propeller shaft is equipped with a lubrication fitting. Use a multi-purpose NLGI Grade 2 EP lubricant. The factory installed universal joints are lubricated for the life of the vehicle and do not need lubrication. All universal joints should be inspected for leakage and damage each time the vehicle is serviced. If seal leakage or damage exists, the universal joint should be replaced. Refer to Maintenance, for additional information. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > General Information > Page 3726 Drive/Propeller Shaft: Description and Operation Propeller Shaft Joint Angle When two shafts come together at a common joint, the bend that is formed is called the operating angle. The larger the angle, the larger the amount of angular acceleration and deceleration of the joint. This speeding up and slowing down of the joint must be canceled to produce a smooth power flow. This is done through the phasing of a propeller shaft and ensuring that the proper propeller shaft joint working angles are maintained. A propeller shaft is properly phased when the yoke ends are in the same plane, or in line. A twisted shaft will make the yokes out of phase and cause a noticeable vibration. When taking propeller shaft joint angle measurements, or checking the phasing, of two piece shafts, consider each shaft separately. Ideally the driveline system should have: Angles that are equal or opposite within 1 degree of each other. - Have a 3 degree maximum operating angle. - Have at least a 1/2 degree continuous operating (propeller shaft) angle. Engine speed (rpm) is the main factor in determining the maximum allowable operating angle. As a guide to the maximum normal operating angles refer to. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3729 Drive/Propeller Shaft: Component Tests and General Diagnostics 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. Unbalance NOTE: Removing and re-indexing the propeller shaft 180° 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. Fig. 4 9. Install a screw clamp at position 1. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3730 Fig. 5 12. If the vibration decreased, install a second clamp and repeat the test. Fig. 6 13. If the additional clamp causes an additional vibration, separate the clamps (1/4 inch above and below the mark). Repeat the vibration test. 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. 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3731 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Adjustments > Adjustment at Axle With Leaf Springs Drive/Propeller Shaft: Adjustments Adjustment at Axle With Leaf Springs Fig. 33 Adjust the pinion shaft angle at the springs with tapered shims. Install tapered shims between the springs and axle pad to correct the angle. Refer to Steering and Suspension, for additional information. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Adjustments > Adjustment at Axle With Leaf Springs > Page 3734 Drive/Propeller Shaft: Adjustments Center Bearing Adjustment Drive away shudder is a vibration that occurs at first acceleration from a stop. Shudder vibration usually peaks at the engines highest torque output. Shudder is a symptom associated with vehicles using a two-piece propeller shaft. To decrease shudder, lower the center bearing in 1/8 inch increments. Use shim stock or fabricated plates. Plate stock must be used to maintain compression of the rubber insulator around the bearing. Do not use washers. Replace the original bolts with the appropriate increased length bolts. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures Drive/Propeller Shaft: Procedures 1. Clean all universal joint bores with cleaning solvent and a wire brush. 2. Inspect the yokes for distortion, cracks, and worn bearing cap bores. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 3737 Drive/Propeller Shaft: Removal and Replacement REMOVAL 1. Raise and support vehicle on safety stands. 2. Shift the transmission to the Neutral position. 3. Using a suitable marker, mark a line across the axle pinion yoke and the propeller shaft yoke for installation reference. 4. Using a suitable marker, mark the outline of the center bearing on the support bracket for installation reference, if equipped. 5. Using a suitable marker, mark the outline of the heat shield on the center bearing for installation reference, if equipped. 6. Remove bolts that attach the center bearing and heat shield to the support bracket, if equipped. 7. Remove the bolts holding the universal joint clamps to the pinion yoke. Fig. 13 8. Slide the slip yoke off of the transmission, or transfer case, output shaft and remove the propeller shaft. INSTALLATION 1. Slide the slip yoke onto the transmission, or transfer case, output shaft. 2. Align the installation reference marks made on the propeller shaft and pinion yoke. 3. Align and install the center bearing and heat shield to the support bracket, if necessary. 4. Install the bolts and tighten to 68 Nm (50 ft. lbs.) torque. 5. Position universal joint into the axle yoke. 6. Tighten the universal joint strap bolts to 19 Nm (14 ft. lbs.) torque. 7. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Page 3738 Drive/Propeller Shaft: Tools and Equipment SPECIAL TOOLS Special Tool 1130 Special Tool 6052 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Joint Universal Joint: Service and Repair Single Cardan Joint DISASSEMBLY 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. Fig. 14 3. Remove snap rings from both sides of yoke. 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. Fig. 15 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Joint > Page 3743 Fig. 16 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. 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 1. Apply extreme pressure (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores to aid in installation. Fig. 17 2. Position the cross in the yoke with its lube fitting, if equipped, pointing up. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Joint > Page 3744 Fig. 18 3. Place a bearing cap over the trunnion and align the cap with the yoke bore. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Joint > Page 3745 Universal Joint: Service and Repair Double Cardan Joint DISASSEMBLY 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. Fig. 19 3. Remove all the bearing cap snap rings. 4. Set the joint in an arbor press or vise with a socket whose inside diameter is large enough to receive the bearing cap positioned beneath the link yoke. Fig. 20 5. Place a socket with an outside diameter smaller than the upper bearing cap on the upper bearing cap and partially press one bearing cap from the outboard side of the link yoke enough to grasp the bearing cap with vise jaws. Be sure to remove grease fittings that interfere with removal. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Joint > Page 3746 Fig. 21 6. Grasp the protruding bearing by vise jaws. Tap the link yoke with a mallet and drift to dislodge the bearing cap from the yoke. Fig. 22 7. Flip assembly and repeat Step 4, Step 5, and Step 6 to remove the opposite bearing cap. This will then allow removal of the cross centering kit assembly and spring. 8. Press the remaining bearing caps out the other end of the link yoke as described above to complete the disassembly. ASSEMBLY During assembly, ensure that the alignment marks on the link yoke and propeller shaft yoke are aligned. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Joint > Page 3747 Fig. 23 2. Fit a cross into the propeller shaft yoke. Fig. 24 3. Place a bearing cap over the trunnion and align the cap with the yoke bore. Keep the needle bearings upright in the bearing assembly. A needle bearing lying at the bottom of the cap will prevent proper assembly. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Joint > Page 3748 Fig. 25 4. Press the bearing cap into the yoke bore enough to install a snap ring. 5. Install a snap ring. Fig. 26 6. Flip the propeller shaft yoke and install the bearing cap onto the opposite trunnion. Install a snap ring. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Joint > Page 3749 Fig. 27 7. Fit the link yoke on the remaining two trunnions and press both bearing caps into place. 8. Install snap rings. Fig. 28 9. Install the centering kit assembly inside the link yoke making sure the spring is properly positioned. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Joint > Page 3750 Fig. 29 10. Place two bearing caps on opposite trunnions of the remaining cross. Fit the open trunnions into the link yoke bores and the bearing caps into the centering kit. Fig. 30 11. Press the remaining two bearing caps into place and install snap rings. Fig. 31 12. Tap the snap rings to allow them to seat into the grooves. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Joint > Page 3751 Fig. 32 13. Check for proper assembly. Flex the joint beyond center it should snap over-center in both directions when correctly assembled. 14. Install the propeller shaft. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > 42/44RE Transmission Flex Plate: Specifications 42/44RE Transmission Bolt, Driveplate To Crankshaft ............................................................................................................. .................................................... 75 Nm (55 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > 42/44RE Transmission > Page 3756 Flex Plate: Specifications 46RE Transmission Bolt, Driveplate To Crankshaft ............................................................................................................. .................................................... 75 Nm (55 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation OVERDRIVE LAMP-PCM OUTPUT This circuit controls a signal for the operation of the push-button overdrive lamp switch. When the lamp is illuminated, the overdrive is disengaged. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3765 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Service Precautions Four-Wheel Drive (4WD) Indicator Lamp: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Service Precautions > Page 3770 Four-Wheel Drive (4WD) Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Four Wheel Drive Lamp ....................................................................................................................... ................................................................. 161 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Testing and Inspection > Four-Wheel Drive Indicator Lamp - Full Time Four-Wheel Drive (4WD) Indicator Lamp: Testing and Inspection Four-Wheel Drive Indicator Lamp - Full Time HARD-WIRED LAMP DIAGNOSIS This lamp depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedure will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS (SUPPLEMENTAL 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. FOUR-WHEEL DRIVE INDICATOR LAMP - FULL TIME The diagnosis found here addresses an inoperative four-wheel drive indicator lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or switch and not with a damaged or inoperative transfer case or transfer case linkage. Refer to Transmission and Drivetrain/Transfer Case/NV242 Diagnosis for more information. If no transfer case problem is found, the following procedure will help locate a short or open in the indicator lamp circuit. For complete circuit diagrams, refer to Complete Body and Chassis Diagrams, See: Diagrams/Electrical Diagrams/Diagrams By Group Number 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. Disconnect the transfer case switch wire harness connector. Check for continuity between the ground circuit cavity of the transfer case 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. Connect the battery negative cable. Turn the ignition switch to the ON position. Install a jumper wire between the full time four wheel drive indicator lamp driver circuit cavity of the transfer case switch wire harness connector and a good ground. The full time four-wheel drive indicator lamp should light. If OK, replace the faulty transfer case switch. 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 cluster. With the transfer case switch wire harness connector still disconnected, check for continuity between the full time four wheel drive indicator lamp driver circuit cavity of the instrument cluster wire harness connector A and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted full time four wheel drive indicator lamp driver circuit as required. 6. Check for continuity between the full time four wheel drive indicator lamp driver circuit cavities of the instrument cluster wire harness connector A and the transfer case switch wire harness connector. There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open full time four wheel drive indicator lamp driver circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Testing and Inspection > Four-Wheel Drive Indicator Lamp - Full Time > Page 3773 Four-Wheel Drive (4WD) Indicator Lamp: Testing and Inspection Four-Wheel Drive Indicator Lamp - Part Time HARD-WIRED LAMP DIAGNOSIS This lamp depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedure will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS (SUPPLEMENTAL 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. FOUR-WHEEL DRIVE INDICATOR LAMP - PART TIME The diagnosis found here addresses an inoperative four-wheel drive indicator lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or switch and not with a damaged or inoperative transfer case or transfer case linkage. Refer to Transmission and Drivetrain/Transfer Case/NV231 Diagnosis or NV242 Diagnosis for more information. If no transfer case problem is found, the following procedure will help locate a short or open in the indicator lamp circuit. For complete circuit diagrams, refer to Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number 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. Disconnect the transfer case switch wire harness connector. Check for continuity between the ground circuit cavity of the transfer case 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. Connect the battery negative cable. Turn the ignition switch to the ON position. Install a jumper wire between the part time four wheel drive indicator lamp driver circuit cavity of the transfer case switch wire harness connector and a good ground. The part time four-wheel drive indicator lamp should light. If OK, replace the faulty transfer case switch. If not OK, go to Step 5. 5. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector at the Controller Anti-Lock Brake (CAB). Remove the instrument cluster. With the transfer case switch wire harness connector still disconnected, check for continuity between the part time four wheel drive indicator lamp driver circuit cavity of the instrument cluster wire harness connector B and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted part time four wheel drive indicator lamp driver circuit as required. 6. Check for continuity between the part time four wheel drive indicator lamp driver circuit cavities of the instrument cluster wire harness connector B and the transfer case switch wire harness connector. There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open part time four wheel drive indicator lamp driver circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3784 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3785 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3791 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3792 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3793 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 The Transmission Relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3797 Transmission Control System Relay: Diagrams Transmission Control Relay Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3798 Transmission Control & Wiper Relays And C106 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3799 Transmission Control System Relay: Description and Operation TRANSMISSION RELAY-PCM OUTPUT The output to this relay provides battery voltage to the overdrive (OD), torque converter clutch (TCC) and governor pressure solenoids. Once battery voltage is applied to the solenoids, they are individually activated by the PCM through OD, TCC and governor pressure outputs. The relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Overdrive Cancel Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3805 Automatic Transmission Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3806 Overdrive Switch: Description and Operation OVERDRIVE/OVERRIDE SWITCH-PCM INPUT On vehicles equipped with an automatic transmission and overdrive, the powertrain control module (PCM) regulates the 3-4 overdrive up-shift and downshift through the overdrive solenoid. This solenoid is located in the transmission. An overdrive/override push-button switch is located at the end of transmission shift lever. The overdrive/override push-button switch is normally open (overdrive allowed) when the lamp is not illuminated. It momentarily closes (overdrive not allowed) when the operator presses the switch and the lamp is illuminated. Overdrive will revert to ON (lamp off) each time the ignition switch in turned on. The transmission downshifts if the operator presses the override switch while in overdrive. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3810 Transmission Position Switch/Sensor: Description and Operation TRANSMISSION PARK/NEUTRAL SWITCH-PCM INPUT The park/neutral switch is located on the transmission housing and provides an input to the Powertrain Control Module (PCM), This will indicate that the automatic transmission is in Park, Neutral or a drive gear selection. This input is used to determine idle speed (varying with gear selection), fuel injector pulse width, ignition timing advance and vehicle speed control operation. The center terminal of the park/neutral position switch is the starter-circuit terminal. It provides the ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. The outer terminals on the switch are for the backup lamp circuit. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3811 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Transmission Speed Sensor: Specifications Sensor Mounting ................................................................................................................................. ..................................................... 27 Nm (20 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3815 Output Shaft Speed Sensor, Park/Neutral Switch, Transmission Solenoid 8-Way Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3816 Output Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input Transmission Speed Sensor: Description and Operation Output Shaft Speed Sensor-PCM Input This sensor generates a signal to the PCM relating to the speed of the transmission main drive shaft. NOTE: This input is used with 4-speed electronic transmissions only. CIRCUIT OPERATION Four Speed Automatic Transmission The output shaft speed sensor generates a signal indicating the speed of the transmission output shaft. Circuits T13 and T14 connect the sensor to the Powertrain Control Module (PCM). Circuit T13 connects to cavity B25 of the PCM. Circuit T14 connects to cavity B28. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input > Page 3819 Transmission Speed Sensor: Description and Operation Sensor Operation The speed sensor is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. The vehicle speed sensor also serves as a backup for the transmission speed sensor. Signals from this sensor are shared with the powertrain control module. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 3820 Transmission Speed Sensor: Service and Repair Removal Transmission Speed Sensor Removal Installation 1. Remove transmission speed sensor and O-ring seal from overdrive case. Installation 1. Install transmission speed sensor and O-ring seal in overdrive case. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3824 Transmission Temperature Sensor/Switch: Description and Operation TRANSMISSION TEMPERATURE SENSOR-PCM INPUT This input is used in the shift operation for 4-speed electronic transmissions only. The temperature data is used for: torque converter clutch operation, overdrive shift, low temperature shift compensation, wide open throttle shift strategy and governor pressure transducer calibration. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Locations 4WD Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Diagrams > 231 Transfer Case Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Diagrams > 231 Transfer Case > Page 3831 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications Gear Sensor/Switch: Specifications TIGHTENING SPECIFICATIONS Switch, Indicator .................................................................................................................................. .......................................................... 15-25 ft. lbs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications NV231 Transfer Case Transfer Case ...................................................................................................................................... ......................................................... 1.2L (2.5 Pints) NV242 Transfer Case Transfer Case ...................................................................................................................................... ......................................................... 1.3L (2.8 Pints) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 3840 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid MOPAR Dexron II, or ATF Plus 3 type 9602 automatic transmission fluid Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Page 3841 Fluid - Transfer Case: Service Precautions DO NOT over fill transfer case beyond normal fluid level. Fluid foaming and damage may occur. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid Pump, Transfer Case > Component Information > Specifications Fluid Pump: Specifications Screw, Oil Pump 12-15 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Service Precautions Four-Wheel Drive (4WD) Indicator Lamp: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Service Precautions > Page 3848 Four-Wheel Drive (4WD) Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Four Wheel Drive Lamp ....................................................................................................................... ................................................................. 161 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Testing and Inspection > Four-Wheel Drive Indicator Lamp Full Time Four-Wheel Drive (4WD) Indicator Lamp: Testing and Inspection Four-Wheel Drive Indicator Lamp - Full Time HARD-WIRED LAMP DIAGNOSIS This lamp depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedure will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS (SUPPLEMENTAL 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. FOUR-WHEEL DRIVE INDICATOR LAMP - FULL TIME The diagnosis found here addresses an inoperative four-wheel drive indicator lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or switch and not with a damaged or inoperative transfer case or transfer case linkage. Refer to Transmission and Drivetrain/Transfer Case/NV242 Diagnosis for more information. If no transfer case problem is found, the following procedure will help locate a short or open in the indicator lamp circuit. For complete circuit diagrams, refer to Complete Body and Chassis Diagrams, See: Diagrams/Electrical Diagrams/Diagrams By Group Number 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. Disconnect the transfer case switch wire harness connector. Check for continuity between the ground circuit cavity of the transfer case 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. Connect the battery negative cable. Turn the ignition switch to the ON position. Install a jumper wire between the full time four wheel drive indicator lamp driver circuit cavity of the transfer case switch wire harness connector and a good ground. The full time four-wheel drive indicator lamp should light. If OK, replace the faulty transfer case switch. 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 cluster. With the transfer case switch wire harness connector still disconnected, check for continuity between the full time four wheel drive indicator lamp driver circuit cavity of the instrument cluster wire harness connector A and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted full time four wheel drive indicator lamp driver circuit as required. 6. Check for continuity between the full time four wheel drive indicator lamp driver circuit cavities of the instrument cluster wire harness connector A and the transfer case switch wire harness connector. There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open full time four wheel drive indicator lamp driver circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Testing and Inspection > Four-Wheel Drive Indicator Lamp Full Time > Page 3851 Four-Wheel Drive (4WD) Indicator Lamp: Testing and Inspection Four-Wheel Drive Indicator Lamp - Part Time HARD-WIRED LAMP DIAGNOSIS This lamp depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedure will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS (SUPPLEMENTAL 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. FOUR-WHEEL DRIVE INDICATOR LAMP - PART TIME The diagnosis found here addresses an inoperative four-wheel drive indicator lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or switch and not with a damaged or inoperative transfer case or transfer case linkage. Refer to Transmission and Drivetrain/Transfer Case/NV231 Diagnosis or NV242 Diagnosis for more information. If no transfer case problem is found, the following procedure will help locate a short or open in the indicator lamp circuit. For complete circuit diagrams, refer to Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number 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. Disconnect the transfer case switch wire harness connector. Check for continuity between the ground circuit cavity of the transfer case 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. Connect the battery negative cable. Turn the ignition switch to the ON position. Install a jumper wire between the part time four wheel drive indicator lamp driver circuit cavity of the transfer case switch wire harness connector and a good ground. The part time four-wheel drive indicator lamp should light. If OK, replace the faulty transfer case switch. If not OK, go to Step 5. 5. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector at the Controller Anti-Lock Brake (CAB). Remove the instrument cluster. With the transfer case switch wire harness connector still disconnected, check for continuity between the part time four wheel drive indicator lamp driver circuit cavity of the instrument cluster wire harness connector B and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted part time four wheel drive indicator lamp driver circuit as required. 6. Check for continuity between the part time four wheel drive indicator lamp driver circuit cavities of the instrument cluster wire harness connector B and the transfer case switch wire harness connector. There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open part time four wheel drive indicator lamp driver circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Locations 4WD Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Diagrams > 231 Transfer Case Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Diagrams > 231 Transfer Case > Page 3857 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications Gear Sensor/Switch: Specifications TIGHTENING SPECIFICATIONS Switch, Indicator .................................................................................................................................. .......................................................... 15-25 ft. lbs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Service Precautions Four-Wheel Drive (4WD) Indicator Lamp: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Service Precautions > Page 3865 Four-Wheel Drive (4WD) Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Four Wheel Drive Lamp ....................................................................................................................... ................................................................. 161 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Testing and Inspection > Four-Wheel Drive Indicator Lamp - Full Time Four-Wheel Drive (4WD) Indicator Lamp: Testing and Inspection Four-Wheel Drive Indicator Lamp - Full Time HARD-WIRED LAMP DIAGNOSIS This lamp depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedure will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS (SUPPLEMENTAL 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. FOUR-WHEEL DRIVE INDICATOR LAMP - FULL TIME The diagnosis found here addresses an inoperative four-wheel drive indicator lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or switch and not with a damaged or inoperative transfer case or transfer case linkage. Refer to Transmission and Drivetrain/Transfer Case/NV242 Diagnosis for more information. If no transfer case problem is found, the following procedure will help locate a short or open in the indicator lamp circuit. For complete circuit diagrams, refer to Complete Body and Chassis Diagrams, See: Diagrams/Electrical Diagrams/Diagrams By Group Number 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. Disconnect the transfer case switch wire harness connector. Check for continuity between the ground circuit cavity of the transfer case 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. Connect the battery negative cable. Turn the ignition switch to the ON position. Install a jumper wire between the full time four wheel drive indicator lamp driver circuit cavity of the transfer case switch wire harness connector and a good ground. The full time four-wheel drive indicator lamp should light. If OK, replace the faulty transfer case switch. 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 cluster. With the transfer case switch wire harness connector still disconnected, check for continuity between the full time four wheel drive indicator lamp driver circuit cavity of the instrument cluster wire harness connector A and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted full time four wheel drive indicator lamp driver circuit as required. 6. Check for continuity between the full time four wheel drive indicator lamp driver circuit cavities of the instrument cluster wire harness connector A and the transfer case switch wire harness connector. There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open full time four wheel drive indicator lamp driver circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Testing and Inspection > Four-Wheel Drive Indicator Lamp - Full Time > Page 3868 Four-Wheel Drive (4WD) Indicator Lamp: Testing and Inspection Four-Wheel Drive Indicator Lamp - Part Time HARD-WIRED LAMP DIAGNOSIS This lamp depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedure will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS (SUPPLEMENTAL 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. FOUR-WHEEL DRIVE INDICATOR LAMP - PART TIME The diagnosis found here addresses an inoperative four-wheel drive indicator lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or switch and not with a damaged or inoperative transfer case or transfer case linkage. Refer to Transmission and Drivetrain/Transfer Case/NV231 Diagnosis or NV242 Diagnosis for more information. If no transfer case problem is found, the following procedure will help locate a short or open in the indicator lamp circuit. For complete circuit diagrams, refer to Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number 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. Disconnect the transfer case switch wire harness connector. Check for continuity between the ground circuit cavity of the transfer case 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. Connect the battery negative cable. Turn the ignition switch to the ON position. Install a jumper wire between the part time four wheel drive indicator lamp driver circuit cavity of the transfer case switch wire harness connector and a good ground. The part time four-wheel drive indicator lamp should light. If OK, replace the faulty transfer case switch. If not OK, go to Step 5. 5. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector at the Controller Anti-Lock Brake (CAB). Remove the instrument cluster. With the transfer case switch wire harness connector still disconnected, check for continuity between the part time four wheel drive indicator lamp driver circuit cavity of the instrument cluster wire harness connector B and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted part time four wheel drive indicator lamp driver circuit as required. 6. Check for continuity between the part time four wheel drive indicator lamp driver circuit cavities of the instrument cluster wire harness connector B and the transfer case switch wire harness connector. There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open part time four wheel drive indicator lamp driver circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Yoke/Flange, Transfer Case > Component Information > Specifications > NV231 Transfer Case Output Yoke/Flange: Specifications NV231 Transfer Case TIGHTENING SPECIFICATIONS Nut, Front Yoke ................................................................................................................................... ........................................................ 90-130 ft. lbs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Yoke/Flange, Transfer Case > Component Information > Specifications > NV231 Transfer Case > Page 3873 Output Yoke/Flange: Specifications NV242 Transfer Case TIGHTENING SPECIFICATIONS Nut, Front Yoke ................................................................................................................................... ........................................................ 90-130 ft. lbs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Front Output Shaft Seal Replacement Seals and Gaskets: Service and Repair Front Output Shaft Seal Replacement NV231 Transfer Case REMOVAL 1. Raise vehicle. 2. Remove front propeller shaft. 3. Remove front output shaft yoke. Fig. 4 4. Remove seal from front case with pry tool. INSTALLATION 1. Install new front output seal in front case with Installer Tool 8143 as follows: a. Place new seal on tool. Garter spring on seal goes toward interior of case. Fig. 5 b. Start seal in bore with light taps from hammer. Once seal is started, continue tapping seal into bore until installer tool seats against case. NV242 Transfer Case REMOVAL 1. Raise vehicle. 2. Remove front propeller shaft. 3. Remove front output shaft yoke. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Front Output Shaft Seal Replacement > Page 3878 Fig. 5 4. Remove seal from front case with pry tool. INSTALLATION 1. Install new front output seal in front case with Installer Tool 6952-A as follows: a. Place new seal on tool. Garter spring on seal goes toward interior of case. Fig. 6 b. Start seal in bore with light taps from hammer. Once seal is started, continue tapping seal into bore until installer tool seats against case. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Front Output Shaft Seal Replacement > Page 3879 Seals and Gaskets: Service and Repair Rear Retainer Bushing and Seal Replacement NV231 Transfer Case REMOVAL 1. Raise vehicle. 2. Remove rear propeller shaft. 3. Using a suitable pry tool or slide-hammer mounted screw, remove the rear retainer seal. Fig. 6 4. Using Remover 6957, remove bushing from rear retainer. INSTALLATION 1. Clean fluid residue from sealing surface and inspect for defects. 2. Position replacement bushing in rear retainer with fluid port in bushing aligned with slot in retainer. Fig. 7 3. Using Installer 8160, drive bushing into retainer until installer seats against case. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Front Output Shaft Seal Replacement > Page 3880 Fig. 8 4. Using Installer C-3995-A, install seal in rear retainer. 5. Install propeller shaft. 6. Verify proper fluid level. 7. Lower vehicle. NV242 Transfer Case REMOVAL 1. Raise vehicle. 2. Remove rear propeller shaft. 3. Using a suitable pry tool or slide-hammer mounted screw, remove the rear retainer seal. Fig. 7 4. Using Remover 6957, remove bushing from rear retainer. INSTALLATION 1. Clean fluid residue from sealing surface and inspect for defects. 2. Position replacement bushing in rear retainer with fluid port in bushing aligned with slot in retainer. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Front Output Shaft Seal Replacement > Page 3881 Fig. 8 3. Using Installer 8160, drive bushing into retainer until installer seats against case. Fig. 9 4. Using Installer C-3995-A, install seal in rear retainer. 5. Install propeller shaft. 6. Verify proper fluid level. 7. Lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Locations 4WD Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Diagrams > 231 Transfer Case Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Diagrams > 231 Transfer Case > Page 3888 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications Gear Sensor/Switch: Specifications TIGHTENING SPECIFICATIONS Switch, Indicator .................................................................................................................................. .......................................................... 15-25 ft. lbs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Specifications Shifter Transfer Case: Specifications TIGHTENING SPECIFICATIONS Nut, Range Lever ................................................................................................................................ ........................................................... 20-25 ft. lbs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Service and Repair > NV231 Transfer Case Shifter Transfer Case: Service and Repair NV231 Transfer Case REMOVAL 1. Shift transfer case into 4L. 2. Remove transfer case shifter knob cap. 3. Remove nut holding shifter knob to shift lever. 4. Remove shifter knob. 5. Raise and support vehicle. Fig. 3 6. Loosen adjusting trunnion lock bolt and slide shift rod out of trunnion. If rod lacks enough travel to come out of trunnion, push trunnion out of shift lever. 7. Remove bolts holding shift lever to transmission. 8. Separate shift lever from vehicle. INSTALLATION 1. Position shift lever on transmission. Use care when passing the shift lever through the shifter boot to prevent damage to the shifter boot. 2. Install bolts to hold shift lever to transmission. 3. Install trunnion to shift lever, if necessary. 4. Install shift rod to trunnion, if necessary. 5. Move shift lever and transfer case to 4L position. 6. Tighten trunnion lock bolt. 7. Lower vehicle. 8. Install shift knob on shift lever. 9. Install nut to hold shifter knob to shift lever. 10. Install shifter knob cap. 11. Verify transfer case operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Service and Repair > NV231 Transfer Case > Page 3897 Shifter Transfer Case: Service and Repair NV242 Transfer Case REMOVAL 1. Shift transfer case into 4L. 2. Remove transfer case shifter knob cap. 3. Remove nut holding shifter knob to shift lever. 4. Remove shifter knob. 5. Raise and support vehicle. Fig. 4 6. Loosen adjusting trunnion lock bolt and slide shift rod out of trunnion. If rod lacks enough travel to come out of trunnion, push trunnion out of shift lever. 7. Remove bolts holding shift lever to transmission. 8. Separate shift lever from vehicle. INSTALLATION 1. Position shift lever on transmission. Use care when passing the shift lever through the shifter boot to prevent damage to the shifter boot. 2. Install bolts to hold shift lever to transmission. 3. Install trunnion to shift lever, if necessary. 4. Install shift rod to trunnion, if necessary. 5. Move shift lever and transfer case to 4L position. 6. Tighten trunnion lock bolt. 7. Lower vehicle. 8. Install shift knob on shift lever. 9. Install nut to hold shifter knob to shift lever. 10. Install shifter knob cap. 11. Verify transfer case operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Mount > Component Information > Specifications Transfer Case Mount: Specifications Rear Support Plate-to-Transfer Case Bolts 30 ft.lb Transfer Case-to-Insulator Mounting Plate Nuts 150 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: Customer Interest A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3912 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3918 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Component Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Component Locations > Page 3923 Output Shaft Speed Sensor, Park/Neutral Switch, Transmission Solenoid 8-Way Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3924 Automatic Transmission Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3925 Shift Solenoid: Description and Operation THREE-FOUR SHIFT SOLENOID-PCM OUTPUT This output is used to control the transmission three-four shift solenoid. It is used on 4-speed electronically controlled automatic transmissions only. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3929 Automatic Transmission Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3930 Torque Converter Clutch Solenoid: Description and Operation TORQUE CONVERTOR CLUTCH (TCC) SOLENOID-PCM OUTPUT This circuit controls operation of the transmission mounted torque convertor clutch (TCC) solenoid used for torque convertor engagement. The powertrain control module (PCM) will determine when to engage and disengage the solenoid by monitoring vehicle miles per hour (mph) versus the output voltage of the throttle position sensor. Also needed are various inputs from: Transmission temperature sensor - Output shaft speed sensor - Module timer - Engine rpm - MAP sensor - Brake switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 > Description and Operation Overdrive Indicator Lamp: Description and Operation OVERDRIVE LAMP-PCM OUTPUT This circuit controls a signal for the operation of the push-button overdrive lamp switch. When the lamp is illuminated, the overdrive is disengaged. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3939 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Service Precautions Four-Wheel Drive (4WD) Indicator Lamp: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Service Precautions > Page 3944 Four-Wheel Drive (4WD) Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Four Wheel Drive Lamp ....................................................................................................................... ................................................................. 161 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Testing and Inspection > Four-Wheel Drive Indicator Lamp - Full Time Four-Wheel Drive (4WD) Indicator Lamp: Testing and Inspection Four-Wheel Drive Indicator Lamp - Full Time HARD-WIRED LAMP DIAGNOSIS This lamp depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedure will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS (SUPPLEMENTAL 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. FOUR-WHEEL DRIVE INDICATOR LAMP - FULL TIME The diagnosis found here addresses an inoperative four-wheel drive indicator lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or switch and not with a damaged or inoperative transfer case or transfer case linkage. Refer to Transmission and Drivetrain/Transfer Case/NV242 Diagnosis for more information. If no transfer case problem is found, the following procedure will help locate a short or open in the indicator lamp circuit. For complete circuit diagrams, refer to Complete Body and Chassis Diagrams, See: Diagrams/Electrical Diagrams/Diagrams By Group Number 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. Disconnect the transfer case switch wire harness connector. Check for continuity between the ground circuit cavity of the transfer case 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. Connect the battery negative cable. Turn the ignition switch to the ON position. Install a jumper wire between the full time four wheel drive indicator lamp driver circuit cavity of the transfer case switch wire harness connector and a good ground. The full time four-wheel drive indicator lamp should light. If OK, replace the faulty transfer case switch. 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 cluster. With the transfer case switch wire harness connector still disconnected, check for continuity between the full time four wheel drive indicator lamp driver circuit cavity of the instrument cluster wire harness connector A and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted full time four wheel drive indicator lamp driver circuit as required. 6. Check for continuity between the full time four wheel drive indicator lamp driver circuit cavities of the instrument cluster wire harness connector A and the transfer case switch wire harness connector. There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open full time four wheel drive indicator lamp driver circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Testing and Inspection > Four-Wheel Drive Indicator Lamp - Full Time > Page 3947 Four-Wheel Drive (4WD) Indicator Lamp: Testing and Inspection Four-Wheel Drive Indicator Lamp - Part Time HARD-WIRED LAMP DIAGNOSIS This lamp depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedure will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS (SUPPLEMENTAL 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. FOUR-WHEEL DRIVE INDICATOR LAMP - PART TIME The diagnosis found here addresses an inoperative four-wheel drive indicator lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or switch and not with a damaged or inoperative transfer case or transfer case linkage. Refer to Transmission and Drivetrain/Transfer Case/NV231 Diagnosis or NV242 Diagnosis for more information. If no transfer case problem is found, the following procedure will help locate a short or open in the indicator lamp circuit. For complete circuit diagrams, refer to Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number 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. Disconnect the transfer case switch wire harness connector. Check for continuity between the ground circuit cavity of the transfer case 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. Connect the battery negative cable. Turn the ignition switch to the ON position. Install a jumper wire between the part time four wheel drive indicator lamp driver circuit cavity of the transfer case switch wire harness connector and a good ground. The part time four-wheel drive indicator lamp should light. If OK, replace the faulty transfer case switch. If not OK, go to Step 5. 5. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector at the Controller Anti-Lock Brake (CAB). Remove the instrument cluster. With the transfer case switch wire harness connector still disconnected, check for continuity between the part time four wheel drive indicator lamp driver circuit cavity of the instrument cluster wire harness connector B and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted part time four wheel drive indicator lamp driver circuit as required. 6. Check for continuity between the part time four wheel drive indicator lamp driver circuit cavities of the instrument cluster wire harness connector B and the transfer case switch wire harness connector. There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open part time four wheel drive indicator lamp driver circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3958 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3959 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3965 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3966 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3967 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 The Transmission Relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3971 Transmission Control System Relay: Diagrams Transmission Control Relay Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3972 Transmission Control & Wiper Relays And C106 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3973 Transmission Control System Relay: Description and Operation TRANSMISSION RELAY-PCM OUTPUT The output to this relay provides battery voltage to the overdrive (OD), torque converter clutch (TCC) and governor pressure solenoids. Once battery voltage is applied to the solenoids, they are individually activated by the PCM through OD, TCC and governor pressure outputs. The relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Overdrive Cancel Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3979 Automatic Transmission Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3980 Overdrive Switch: Description and Operation OVERDRIVE/OVERRIDE SWITCH-PCM INPUT On vehicles equipped with an automatic transmission and overdrive, the powertrain control module (PCM) regulates the 3-4 overdrive up-shift and downshift through the overdrive solenoid. This solenoid is located in the transmission. An overdrive/override push-button switch is located at the end of transmission shift lever. The overdrive/override push-button switch is normally open (overdrive allowed) when the lamp is not illuminated. It momentarily closes (overdrive not allowed) when the operator presses the switch and the lamp is illuminated. Overdrive will revert to ON (lamp off) each time the ignition switch in turned on. The transmission downshifts if the operator presses the override switch while in overdrive. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3984 Transmission Position Switch/Sensor: Description and Operation TRANSMISSION PARK/NEUTRAL SWITCH-PCM INPUT The park/neutral switch is located on the transmission housing and provides an input to the Powertrain Control Module (PCM), This will indicate that the automatic transmission is in Park, Neutral or a drive gear selection. This input is used to determine idle speed (varying with gear selection), fuel injector pulse width, ignition timing advance and vehicle speed control operation. The center terminal of the park/neutral position switch is the starter-circuit terminal. It provides the ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. The outer terminals on the switch are for the backup lamp circuit. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3985 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Transmission Speed Sensor: Specifications Sensor Mounting ................................................................................................................................. ..................................................... 27 Nm (20 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3989 Output Shaft Speed Sensor, Park/Neutral Switch, Transmission Solenoid 8-Way Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3990 Output Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input Transmission Speed Sensor: Description and Operation Output Shaft Speed Sensor-PCM Input This sensor generates a signal to the PCM relating to the speed of the transmission main drive shaft. NOTE: This input is used with 4-speed electronic transmissions only. CIRCUIT OPERATION Four Speed Automatic Transmission The output shaft speed sensor generates a signal indicating the speed of the transmission output shaft. Circuits T13 and T14 connect the sensor to the Powertrain Control Module (PCM). Circuit T13 connects to cavity B25 of the PCM. Circuit T14 connects to cavity B28. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input > Page 3993 Transmission Speed Sensor: Description and Operation Sensor Operation The speed sensor is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. The vehicle speed sensor also serves as a backup for the transmission speed sensor. Signals from this sensor are shared with the powertrain control module. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 3994 Transmission Speed Sensor: Service and Repair Removal Transmission Speed Sensor Removal Installation 1. Remove transmission speed sensor and O-ring seal from overdrive case. Installation 1. Install transmission speed sensor and O-ring seal in overdrive case. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 3998 Transmission Temperature Sensor/Switch: Description and Operation TRANSMISSION TEMPERATURE SENSOR-PCM INPUT This input is used in the shift operation for 4-speed electronic transmissions only. The temperature data is used for: torque converter clutch operation, overdrive shift, low temperature shift compensation, wide open throttle shift strategy and governor pressure transducer calibration. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Locations 4WD Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Diagrams > 231 Transfer Case Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Diagrams > 231 Transfer Case > Page 4005 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications Gear Sensor/Switch: Specifications TIGHTENING SPECIFICATIONS Switch, Indicator .................................................................................................................................. .......................................................... 15-25 ft. lbs. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Application and ID ABS Light: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Anti-lock Brake = Bulb Number PC194 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation > Rear Wheel Antilock Brakes ABS Light: Description and Operation Rear Wheel Antilock Brakes The amber ABS warning lamp is used to alert the driver of an RWAL problem and identify DTCs stored in the CABs memory. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation > Rear Wheel Antilock Brakes > Page 4016 ABS Light: Description and Operation Four Wheel Antilock Brakes The amber ABS warning lamp is located in the instrument cluster. The lamp illuminates at start-up to perform a self check. The lamp goes out when the self check program determines the system is operating normal. If an ABS component exhibits a fault the CAB will illuminate the lamp and register a trouble code in the microprocessor. The lamp is controlled by the CAB. The CAB controls the lamp sending a message to the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Diagrams Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations Brake Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations > Page 4023 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations Diagnostic Connector - ABS: Locations NOTE: Chrysler does not provide a procedrure to retrieve ABS diagnostic trouble codes without a scan tool Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications REAR WHEEL ANTILOCK (RWAL) BRAKES: Mounting Screws ................................................................................................................................. ................................................ 6 Nm (53 inch lbs.) FOUR WHEEL ANTILOCK BRAKES: CAB Screws ........................................................................................................................................ ................................ 4 - 4.7 Nm (36 - 42 inch lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > EBC 2 Antilock Brake Controller (EBC) 2 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > EBC 2 > Page 4032 Antilock Brake Controller (EBC) 325 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Connector Plug C1 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Connector Plug C1 > Page 4035 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > Controller Antilock Brake (CAB) Electronic Brake Control Module: Description and Operation Controller Antilock Brake (CAB) The controller antilock brake module is used to monitor wheel speeds and modulates (control) hydraulic pressure in each brake channel. The modulated hydraulic pressure is used to prevent wheel lock up during braking. The CAB also provides a vehicle speed signal (VSS) to the powertrain control module. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > Controller Antilock Brake (CAB) > Page 4038 Electronic Brake Control Module: Description and Operation With Four Wheel Antilock Brakes 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. The CAB contains dual microprocessors. A logic block in each microprocessor receives identical sensor signals. These signals are processed and compared simultaneously. 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. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > Controller Antilock Brake (CAB) > Page 4039 Electronic Brake Control Module: Description and Operation With Rear Wheel Antilock Brakes 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. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. 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 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. 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 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System Electronic Brake Control Module: Service and Repair Four Wheel Antilock Brake System NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. REMOVAL 1. Disconnect battery negative cable. Harness Connector Locks 2. Push the harness connector locks to release the locks, then remove the connectors from the CAB. Pump Motor Connector 3. Disconnect the pump motor connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 4042 Controller Mounting Screws 4. Remove screws attaching CAB to the HCU. 5. Remove the CAB. INSTALLATION 1. Place the CAB onto the HCU. NOTE: Insure the CAB seal is in position before installation. 2. Install the mounting screws and tighten to 4 - 4.7 Nm (36 - 42 inch lbs.). 3. Connect the pump motor harness. 4. Connect the harnesses to the CAB and lock the connectors. 5. Connect battery. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 4043 Electronic Brake Control Module: Service and Repair Rear Wheel Antilock Brake System NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. REMOVAL RWAL Controller 1. Push the CAB harness connector lock to release the lock and remove the connector from the controller. 2. Remove the RWAL valve harness connector from the controller. 3. Remove the controller mounting screws and remove the controller from the mounting bracket. INSTALLATION 1. Position the controller on the bracket. 2. Install the mounting screws and tighten to 6 Nm (53 inch 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications REAR WHEEL ANTILOCK (RWAL) BRAKES: Mounting Bolt ....................................................................................................................................... ................................. 20 - 27 Nm (15 - 20 ft. lbs.) FOUR WHEEL ANTILOCK BRAKES: Bracket Bolts ....................................................................................................................................... ................................... 14 - 15 Nm (10 - 12 ft. lbs.) Mounting Nuts ..................................................... ............................................................................................................................ 12 Nm (102 inch lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Locations > Kelsey-Hayes EBC 2 EBC 2 ABS Components Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Locations > Kelsey-Hayes EBC 2 > Page 4049 EBC 325 ABS Components Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Locations > Page 4050 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > With Four Wheel Antilock Brakes Hydraulic Control Assembly - Antilock Brakes: Description and Operation With Four Wheel Antilock Brakes The Hydraulic Control Unit (HCU) consists of a valve body, pump, two accumulators and a motor. 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. 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 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. 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 wheel speeds. This cycle controls re-application of fluid apply pressure due to changing road surfaces or wheel speed. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > With Four Wheel Antilock Brakes > Page 4053 Hydraulic Control Assembly - Antilock Brakes: Description and Operation With Rear Wheel Antilock Brakes 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Front Antilock Valve Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Front Antilock Valve Replacement NOTE: If the antilock control assembly needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. 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. Mounting Bracket 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Front Antilock Valve Replacement > Page 4056 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Rear Antilock Valve Replacement 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Rear Wheel Anti-Lock (RWAL) Brakes Mounting Bolt 200 in.lb Front Wheel Anti-Lock Brakes Front Sensor Bolt 190 in.lb Rear Sensor Bolt 200 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Rear Wheel Speed Sensor Tone Wheel Front Wheel Speed Sensor Rear Wheel Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4062 Wheel Speed Sensor: Connector Locations Left Front Wheel Speed Sensor Connector Right Front Wheel Speed Sensor Connector Rear Wheel Speed Sensor Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Front Wheel Speed Sensor: Diagrams Front Connector Pin Identification Connector Pin Identification Connector Pin Identification Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Front > Page 4065 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes Wheel Speed Sensor: Description and Operation Four Wheel Antilock Brakes The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front steering knuckles. The third sensor is mounted on top of the rear axle differential housing. The sensor is a magnet coil that is mounted over a tone wheel front/exciter ring rear with an air gap between them. The sensors measure the wheel speed by monitoring the rotation of the tone wheels front/exciter ring rear. As the teeth of the tone wheels front/exciter ring rear move through the magnetic field of the sensor an AC voltage is generated. This signal frequency increases or decreases proportionally to the speed of the wheel. The CAB monitors these signals for changes in wheel deceleration. If the CAB detects a sudden wheel or wheels deceleration within a predetermined amount the CAB will activate the ABS system. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 4068 Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brakes Rear Wheel Speed Sensor Location The rear Wheel Speed Sensor (WSS) is mounted in the rear differential housing. 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. Exciter Ring Location The exciter ring is press fitted onto the differential carrier next to the final drive ring gear. Operation Of The Wheel Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 4069 When the ring gear is rotated, the exciter ring passes the tip of the WSS. As the exciter ring passes the tip of the WSS, the magnetic lines of force of the sensor are cut, causing the magnetic field to be moved across the sensor's windings. This, in turn causes current to flow through the WSS circuit. 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 rotates, the stronger the signal will be - Distance between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring, 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. Data Link Connector - Typical The assembly plant performs a "Rolls Test" on every vehicle that leaves the assembly plant. One of the tests 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Front CAUTION: Special bolts are used to attach the front sensor. The bolts have a special shoulder, thread length and surface treatment. If the original bolts must be replaced, use only factory replacement bolts. Do not use substitute bolt under any circumstances. REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper and rotor. Front Wheel Speed Sensor - 4X4 4. Remove bolts attaching sensor to hub/bearing. 5. Remove clamps securing sensor wire to control arm and inner fender panel. 6. In engine compartment, disconnect sensor wire and remove sensor. INSTALLATION 1. Guide sensor wire around upper control arm. 2. Position sensor on hub/bearing and install attaching bolts. Tighten bolt to 18 - 25 Nm (160 - 220 inch lbs.). 3. Secure sensor wire retaining clamps to control arm and fender panel with original hardware. 4. In engine compartment, connect sensor wire to harness connector. Insure wire is routed away from hot or rotating underhood components. 5. Install brake rotor and caliper. 6. Install wheel and tire assembly. 7. Turn steering wheel back and forth that wire is clear of steering and suspension components. 8. Remove supports and lower vehicle. With Rear Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4072 Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 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. With Four Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4073 Wheel Speed Sensor: Service and Repair Tone Wheel Replacement Front Tone Wheel Tone Wheel 4X2 The tone wheel for the front speed sensor is located on the hub/bearing on 2-wheel drive models. On 4-wheel drive models, the tone wheel is located in the hub/bearing housing. The tone wheel is not a serviceable component. To replace the tone wheel the hub/bearing must be replaced. Rear Tone Wheel The toothed exciter ring is press-fitted onto the differential carrier next to the final drive ring gear in the differential case. If the ring is damaged, refer to Transmission and Drivetrain for service procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures W/ Four Wheel Antilock Brakes ABS system bleeding requires conventional bleeding methods plus use of the DRB scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. W/ Rear Wheel Antilock Brakes 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. Do not pump the brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles that are distributed throughout the hydraulic system. This will make additional bleeding operations necessary. Do not allow the master cylinder to run out of fluid during bleed operations. An empty cylinder will allow additional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed. Bleed only one brake component at a time in the following sequence: Master Cylinder - Combination Valve - Rear Antilock Valve - Left Rear Wheel - Right Rear Wheel - Right Front Wheel - Left Front Wheel MANUAL BLEEDING 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. Bleed Hose Setup 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 4078 PRESSURE BLEEDING 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 the adapter provided with the equipment or Adapter 6921. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 4079 Brake Bleeding: Service and Repair Base Brake System 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. Do not pump the brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles that are distributed throughout the hydraulic system. This will make additional bleeding operations necessary. Do not allow the master cylinder to run out of fluid during bleed operations. An empty cylinder will allow additional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed. Bleed only one brake component at a time in the following sequence: Master Cylinder - Combination Valve - Rear Antilock Valve - Right Rear Wheel - Left Rear Wheel - Right Front Wheel - Left Front Wheel MANUAL BLEEDING 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. Bleed Hose Setup 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. PRESSURE BLEEDING 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation Brake Pedal Assy: Description and Operation 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation > Page 4083 Brake Pedal Assy: Service and Repair REMOVAL 1. Remove stop lamp switch. Brake Pedal Mounting 2. Remove clip securing booster push rod to brake pedal. 3. Remove pedal pivot pin C-clip and slide pin out of support bracket and pedal. 4. Remove pedal and bushings. INSTALLATION 1. Replace bushings if worn or damaged. 2. Lubricate pedal bushings and pivot pin with Mopar multi mileage grease, Lubriplate, or a silicone grease. 3. Install bushings in pedal and position pedal in support. 4. Insert pivot pin through support and pedal bushings and install C-clip. 5. Install booster push rod on brake pedal and install push rod retainer clip. 6. Install stop lamp switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Service Precautions Brake Warning Indicator: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Service Precautions > Page 4087 Brake Warning Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Brake Warning ..................................................................................................................................... ............................................................. PC194 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > General Information Brake Warning Indicator: Description and Operation General Information A red warning lamp is used for the service brake portion of the hydraulic system. The lamp is located in the instrument cluster. The red warning light alerts the driver if a pressure differential exists between the front and rear hydraulic systems or the parking brakes are applied. The lamp is turned on momentarily when the ignition switch is turn to the on position. This is a self test to verify the lamp is operational. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > General Information > Page 4090 Brake Warning Indicator: Description and Operation Brake Warning Lamp Description The red brake warning lamp is used to alert the driver of a hydraulic fault or that the parking brake is applied. For the RWAL system, the red brake warning lamp also is used to alerts the driver of a problem with the RWAL system. The brake warning lamp illuminates when a message is sent over the bus to the cluster to illuminate the bulb. A ground for the bulb is provided when: The brakes are applied and the park brake switch is actuated. - A hydraulic fault has occurred and the pressure differential switch is actuated. - A RWAL fault has occurred. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Page 4091 Brake Warning Indicator: Testing and Inspection HARD-WIRED LAMP DIAGNOSIS This lamp depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedure will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS (SUPPLEMENTAL 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. BRAKE WARNING LAMP The diagnosis found here addresses an inoperative brake warning lamp condition. If the brake warning lamp stays on with the ignition switch in the ON position and the park brake released, or comes on while driving, refer to Rear Wheel Antilock for vehicles equipped with a rear wheel anti-lock brake system, or refer to Antilock Brakes for vehicles equipped with a four wheel anti-lock brake system for further diagnosis. If no brake system problem is found, the following procedure will help locate a faulty park brake switch or circuit. For complete circuit diagrams, refer to Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number 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. Thrn 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. Thrn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector at the park brake switch. With the park brake released, check for continuity between the park brake switch terminal and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, adjust or replace the faulty park brake switch. 4. Remove the instrument cluster. With the wire harness connector still disconnected from the park brake switch, check for continuity between the park brake switch sense circuit cavity of the park brake 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 park brake switch sense circuit as required. 5. Check for continuity between the park brake switch sense circuit cavities of the instrument cluster wire harness connector A and the park brake switch wire harness connector. There should be continuity. If OK, refer to Instrument Cluster Instrument Panel Test/Preliminary Diagnosis for further testing of the brake warning lamp and the instrument cluster circuitry. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection If not OK, repair the open park brake switch sense circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair Brake Caliper: Technical Service Bulletins Front Caliper Mounting/Steering Knuckle - Thread Repair NUMBER: 05-03-99 GROUP: Brakes EFFECTIVE DATE: Apr. 23, 1999 SUBJECT: Front Brake Caliper Mounting To Steering Knuckle Thread Repair OVERVIEW: This bulletin involves repair of the threads on the steering knuckle or brake caliper mounting adapter that are used to install and retain the front brake caliper housing in its correct operating location. MODELS: 1986 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango DISCUSSION: A Brake Knuckle Thread Repair Kit has been developed to repair stripped threads on the front brake caliper mounting attachment making it no longer necessary to replace the front steering knuckle/brake caliper mounting adapter when encountering stripped threads. The following information provides the repair procedure for using the Brake Knuckle Thread Repair Kit. DIAGNOSIS: 1. Place the vehicle on an appropriate hoist. 2. Remove the front tire/wheel assembly. 3. Remove the brake caliper housing assembly by loosening the mounting bolts. NOTE: IF HIGH TORQUE IS ENCOUNTERED DURING THE MOUNTING BOLT REMOVAL, IT IS LIKELY THAT THREAD DAMAGE WILL OCCUR OR HAS OCCURRED. 4. Remove the caliper housing assembly and hang the housing on the frame of the vehicle using an appropriate wire hanger. NOTE: DO NOT ALLOW THE CALIPER HOUSING TO HANG BY ITSELF FROM THE BRAKE HOSE AS DAMAGE TO THE HOSE MAY RESULT. 5. If the vehicle has a bolt-on brake caliper mounting adapter, remove the adapter. If the brake caliper mounts directly to the steering knuckle, remove retainers on the wheel studs and remove the rotor. 6. Inspect the mounting bolts and knuckle threads for damage. If either is damaged, it is likely that damage to the other has occurred as well. If damage has occurred to the threads in the form of knicks, thread pulling, or cross-threading, perform the Repair Procedure. PARTS REQUIRED: AR (1) 05016156AA Insert, Heli-Coil, M9 X 1.25 AR (1) 04886075AA Bolts, Caliper Housing Mounting EQUIPMENT REQUIRED: AR (1) 05016155AA Kit, Brake Knuckle Thread Repair Includes: 23/64 Drill Bit M9 X 1.25 Tap Heli-Coil Installation Tool Heli-Coil Tang Break-Off Rod (25) M9 X 1.25 Stainless Steel Heli-Coils REPAIR PROCEDURE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair > Page 4097 1. Using the 23/64 in. drill, drill through the brake caliper mounting attachment hole keeping the drill perpendicular to the knuckle. 2. Using the M9 X 1.25 tap, tap the drilled hole ensuring to tap the hole entirely through. 3. Install a Heli-Coil insert onto the installation tool (tool number 3747-9). Be sure the tang is properly engaged into the driving contour of the tool. 4. Install the Heli-Coil into the drilled/tapped hole by rotating the tool and exerting slight pressure onto the tool/Heli-Coil and into the drilled/tapped hole. Continue to rotate the tool until the insert is located 1/4 to 1/2 turn below the steering knuckle surface. 5. Back the Heli-Coil installation tool out of the installed Heli-Coil. Then, remove the tang from the Heli-Coil by breaking the tang off using the tang break-off tool. Place the break-off tool into the assembled insert until it rests on the Heli-Coil tang. Holding the tool squarely, strike the tool sharply with a hammer. 6. If the vehicle has a bolt-on brake caliper mounting adapter, install the adapter. Refer to the appropriate Service Manual for information regarding proper brake caliper adapter mounting information. If the brake caliper mounts directly to the steering knuckle, install the rotor. 7. Install the caliper using new mounting bolts p/n 04886075AA in any location that had a Heli-Coil installed. Tighten the bolts to 30 - 35 N.m (22-26 ft. lbs.). 8. Install the tire/wheel assembly. 9. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-93 Brake Caliper Mounting Support Thread Repair, Left Side 0.4 Hrs. 05-80-20-94 Brake Caliper Mounting Support Thread Repair, Right Side 0.4 Hrs. 05-80-20-50 Brake Caliper Mounting Support Thread Repair, Each Additional Same Side 0.1 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Page 4098 Brake Caliper: Specifications Bore 2.75 in Mounting Bolts 22 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation REMOVAL 1. Raise and support vehicle. 2. Remove front wheel and tire assemblies. Caliper Brake Hose Connection 3. Disconnect brake hose at caliper. Discard hose fitting washers if worn, or damaged. 4. Remove caliper slide pins. 5. Remove caliper and brake shoes from caliper. INSTALLATION 1. Install brake shoes in caliper. 2. Install 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. Align caliper in adapter and install caliper slide pins. Tighten caliper slide pins to 30 Nm (22 ft. lbs.). 4. Install brake hose to 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. 5. Bleed base brake system. 6. Install wheel and tire assemblies. 7. Remove supports and lower vehicle. 8. Verify firm pedal before moving vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4101 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. Caliper Piston Removal 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 pressure to ease the piston out. WARNING: NEVER ATTEMPT TO CATCH THE PISTON AS IT LEAVES THE BORE. THIS MAY RESULT IN PERSONAL INJURY. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4102 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. Sliding Boot Onto Piston Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4103 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4104 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4105 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, 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 interchange 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 05-05-98 > Oct > 98 > Front Brakes - Grind or Growl Sound Technical Service Bulletin # 05-05-98 Date: 981009 Front Brakes - Grind or Growl Sound NO: 05-05-98 GROUP: Brakes DATE: Oct. 9, 1998 SUBJECT: Brake Grind Or Growl Sound MODELS: 1998 - 1999 (DN) Durango SYMPTOM/CONDITION: Brake grind or growl sound coming from the front brakes during low speed braking (less than five mph (eight kph)). These sounds will usually be heard during light to moderate brake applications and from speeds from zero to five (5) miles per hour (8 kph). During braking, these sounds will be characterized by: ^ Growl/grind noise that may be accompanied by squeal ^ Low frequency grinding noise that may be accompanied by pedal pulsation ^ Steering wheel and seat vibration (in extreme conditions) NOTE: NO REDUCTION IN BRAKING ABILITY OR PARTICULAR DAMAGE TO THE BRAKE SYSTEM WILL RESULT FROM THESE NOISES. DIAGNOSIS: 1. Drive the vehicle on a smooth surfaced road in an area away from heavy traffic and high surrounding noise. 2. Make several stops from a moderate speed to generate some heat within the brake system. 3. Accelerate to 15-20 mph (24-32 kph), then apply moderate pressure to the brake pedal until the vehicle comes to a stop. 4. If a grinding/growling noise is coming from the front brakes perform the Repair Procedure. If there is no noise, drive the vehicle for several miles (kilometers) with minimal brake applications to allow the brake system to cool or park the vehicle until the brakes cool, then repeat Steps 2 and 3 again. If the grinding/growling noise is now coming from the front brakes, perform the Repair Procedure. PARTS REQUIRED: 1 05014095AB Kit, Front Brake Shoe AR (2) 52009208 Rotor, Brake POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-70-22-92 Replace Front Disc Brake Shoes 0.8 Hrs. Relate Operation No: 05-21-10-50 Replace Disc Brake Rotor, Right Side 0.1 Hrs. 05-21-10-51 Replace Disc Brake Rotor, Left Side 0.1 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 05-05-98 > Oct > 98 > Front Brakes - Grind or Growl Sound > Page 4114 Repair Procedure This bulletin involves installing a revised set of front brake shoes. 1. Clean master cylinder reservoir and filler caps. 2. Remove the reservoir filler cap and remove approximately 1/4 of the fluid from the reservoir. Use a clean suction gun or similar device to drain the brake fluid. 3. Raise and support the vehicle. 4. Remove front wheel and tire assemblies. 5. Bottom the caliper pistons in the caliper bores using a large C-clamp. Position the C-clamp frame on the rear of the caliper and clamp screw on the outboard brake shoe. 6. Remove the caliper slide pins. 7. Remove caliper from caliper adapter. CAUTION: DO NOT ALLOW THE CALIPER TO HANG BY THE BRAKE HOSE. USE A HANGER TO SUPPORT THE CALIPER WHILE SERVICING THE BRAKE SHOES. 8. Remove the outboard brake shoe (Figure 1). Pry one end of the shoe retainer spring away from the caliper, then tilt the shoe upward and rotate it out of the caliper. 9. Remove the inboard brake shoe by tilting the shoe outward until the retainer spring is clear of the caliper piston (Figure 2). 10. Remove any dirt or foreign material from the wear surface of the rotor. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 05-05-98 > Oct > 98 > Front Brakes - Grind or Growl Sound > Page 4115 11. Secure a dial indicator onto the steering knuckle so that the plunger of the dial indicator is positioned approximately 25.4 mm (1 in.) inward from the rotor's edge (Figure 3). If the runout exceeds 0.102 mm (0.004 in.), replace the rotor with p/n 52009208. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), page 5-16 for information regarding rotor replacement. 12. Position a micrometer approximately 25.4 mm (1 in.) from the rotor outer circumference (Figure 4) and measure the rotor thickness. Take an additional 6-12 measurements around the rotor. If the thickness of the rotor varies more than 0.013 mm (0.0005 in.) from point to point, replace the rotor with p/n 52009208. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), page 5-16 for information regarding rotor replacement. 13. Install inboard brake shoe from brake shoe kit p/n 05014095AB. Be sure the retainer spring is firmly seated in the caliper piston. 14. Insert outboard brake shoe into the caliper (Figure 5). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 05-05-98 > Oct > 98 > Front Brakes - Grind or Growl Sound > Page 4116 15. Ensure the outboard brake shoe retainer springs are seated in the caliper (Figure 6). 16. Install caliper and brake shoe assembly over the rotor and into the adapter. Be sure the brake shoe tangs are properly seated on the adapter ledges. 17. Install and tighten the caliper slide pins to 25-35 N.m (18-26 ft. lbs.). NOTE: START THE SLIDE PINS BY HAND BEFORE TIGHTENING. DO NOT CROSS THREAD THE PINS. 18. Perform Steps 5 through 17 to the front brakes on the other side of the vehicle. 19. Install the wheel and tire assembly. 20. Remove supports and lower the vehicle. 21. Pump the brake pedal several times to seat the new brake shoes. CAUTION: VERIFY A FIRM BRAKE PEDAL BEFORE MOVING THE VEHICLE. 22. Ensure that the master cylinder reservoir is at the proper level as indicated on the side of the reservoir. Fill the reservoir with Mopar Brake Fluid p/n 04318080. 23. Repeat the Diagnosis to ensure that the brake growl/grind noise has been eliminated. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 05-05-98 > Oct > 98 > Front Brakes - Grind or Growl Sound Technical Service Bulletin # 05-05-98 Date: 981009 Front Brakes - Grind or Growl Sound NO: 05-05-98 GROUP: Brakes DATE: Oct. 9, 1998 SUBJECT: Brake Grind Or Growl Sound MODELS: 1998 - 1999 (DN) Durango SYMPTOM/CONDITION: Brake grind or growl sound coming from the front brakes during low speed braking (less than five mph (eight kph)). These sounds will usually be heard during light to moderate brake applications and from speeds from zero to five (5) miles per hour (8 kph). During braking, these sounds will be characterized by: ^ Growl/grind noise that may be accompanied by squeal ^ Low frequency grinding noise that may be accompanied by pedal pulsation ^ Steering wheel and seat vibration (in extreme conditions) NOTE: NO REDUCTION IN BRAKING ABILITY OR PARTICULAR DAMAGE TO THE BRAKE SYSTEM WILL RESULT FROM THESE NOISES. DIAGNOSIS: 1. Drive the vehicle on a smooth surfaced road in an area away from heavy traffic and high surrounding noise. 2. Make several stops from a moderate speed to generate some heat within the brake system. 3. Accelerate to 15-20 mph (24-32 kph), then apply moderate pressure to the brake pedal until the vehicle comes to a stop. 4. If a grinding/growling noise is coming from the front brakes perform the Repair Procedure. If there is no noise, drive the vehicle for several miles (kilometers) with minimal brake applications to allow the brake system to cool or park the vehicle until the brakes cool, then repeat Steps 2 and 3 again. If the grinding/growling noise is now coming from the front brakes, perform the Repair Procedure. PARTS REQUIRED: 1 05014095AB Kit, Front Brake Shoe AR (2) 52009208 Rotor, Brake POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-70-22-92 Replace Front Disc Brake Shoes 0.8 Hrs. Relate Operation No: 05-21-10-50 Replace Disc Brake Rotor, Right Side 0.1 Hrs. 05-21-10-51 Replace Disc Brake Rotor, Left Side 0.1 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 05-05-98 > Oct > 98 > Front Brakes - Grind or Growl Sound > Page 4122 Repair Procedure This bulletin involves installing a revised set of front brake shoes. 1. Clean master cylinder reservoir and filler caps. 2. Remove the reservoir filler cap and remove approximately 1/4 of the fluid from the reservoir. Use a clean suction gun or similar device to drain the brake fluid. 3. Raise and support the vehicle. 4. Remove front wheel and tire assemblies. 5. Bottom the caliper pistons in the caliper bores using a large C-clamp. Position the C-clamp frame on the rear of the caliper and clamp screw on the outboard brake shoe. 6. Remove the caliper slide pins. 7. Remove caliper from caliper adapter. CAUTION: DO NOT ALLOW THE CALIPER TO HANG BY THE BRAKE HOSE. USE A HANGER TO SUPPORT THE CALIPER WHILE SERVICING THE BRAKE SHOES. 8. Remove the outboard brake shoe (Figure 1). Pry one end of the shoe retainer spring away from the caliper, then tilt the shoe upward and rotate it out of the caliper. 9. Remove the inboard brake shoe by tilting the shoe outward until the retainer spring is clear of the caliper piston (Figure 2). 10. Remove any dirt or foreign material from the wear surface of the rotor. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 05-05-98 > Oct > 98 > Front Brakes - Grind or Growl Sound > Page 4123 11. Secure a dial indicator onto the steering knuckle so that the plunger of the dial indicator is positioned approximately 25.4 mm (1 in.) inward from the rotor's edge (Figure 3). If the runout exceeds 0.102 mm (0.004 in.), replace the rotor with p/n 52009208. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), page 5-16 for information regarding rotor replacement. 12. Position a micrometer approximately 25.4 mm (1 in.) from the rotor outer circumference (Figure 4) and measure the rotor thickness. Take an additional 6-12 measurements around the rotor. If the thickness of the rotor varies more than 0.013 mm (0.0005 in.) from point to point, replace the rotor with p/n 52009208. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), page 5-16 for information regarding rotor replacement. 13. Install inboard brake shoe from brake shoe kit p/n 05014095AB. Be sure the retainer spring is firmly seated in the caliper piston. 14. Insert outboard brake shoe into the caliper (Figure 5). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 05-05-98 > Oct > 98 > Front Brakes - Grind or Growl Sound > Page 4124 15. Ensure the outboard brake shoe retainer springs are seated in the caliper (Figure 6). 16. Install caliper and brake shoe assembly over the rotor and into the adapter. Be sure the brake shoe tangs are properly seated on the adapter ledges. 17. Install and tighten the caliper slide pins to 25-35 N.m (18-26 ft. lbs.). NOTE: START THE SLIDE PINS BY HAND BEFORE TIGHTENING. DO NOT CROSS THREAD THE PINS. 18. Perform Steps 5 through 17 to the front brakes on the other side of the vehicle. 19. Install the wheel and tire assembly. 20. Remove supports and lower the vehicle. 21. Pump the brake pedal several times to seat the new brake shoes. CAUTION: VERIFY A FIRM BRAKE PEDAL BEFORE MOVING THE VEHICLE. 22. Ensure that the master cylinder reservoir is at the proper level as indicated on the side of the reservoir. Fill the reservoir with Mopar Brake Fluid p/n 04318080. 23. Repeat the Diagnosis to ensure that the brake growl/grind noise has been eliminated. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Page 4125 Brake Pad: 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 lining should be replaced when worn to a thickness of 1.6 mm (1/16 inch). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Page 4126 Brake Pad: Service and Repair REMOVAL 1. Clean master cylinder reservoir and filler caps. 2. Remove reservoir filler cap and drain approximately 1/4 of fluid Nm 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. Remove caliper slide pins. Removing Caliper Assembly 7. Remove caliper and brake shoes. Outboard Brake Shoe 8. Remove outboard brake shoe. Pry one end of shoe retainer spring away from caliper. Then tilt shoe upward and rotate it out of caliper. Inboard Brake Shoe Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Page 4127 9. Remove inboard shoe by tilting shoe outward until retainer spring is clear of caliper piston. 10. Support caliper with wire from suspension component. Do not allow brake hose to support caliper weight. INSTALLATION 1. Clean slide surfaces of adapter ledges with a wire brush. Then lubricate surfaces with a thin coat of high temperature grease. 2. Install new slide pin bushings if necessary. 3. Install inboard shoe. Be sure retainer spring is firmly seated in caliper piston. Installing Outboard Shoe 4. Insert outboard brake shoe in caliper. Outboard Shoe Retainer Spring 5. Insure the outboard shoe retainer spring are seated in the caliper. 6. Install caliper and brake shoes over rotor and into adapter. Be sure shoe tangs are properly seated on adapter ledges. 7. Install and tighten caliper slide pins to 25 - 35 Nm (18 - 26 ft. lbs.). Start the slide pins by hand before tightening. Do not cross thread the pins. 8. Install wheel and tire assembly. 9. Remove support and lower vehicle. 10. Pump brake pedal to seat brake shoes. 11. Verify a firm brake pedal before moving vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest for Brake Rotor/Disc: > 05-05-98 > Oct > 98 > Front Brakes Grind or Growl Sound Technical Service Bulletin # 05-05-98 Date: 981009 Front Brakes - Grind or Growl Sound NO: 05-05-98 GROUP: Brakes DATE: Oct. 9, 1998 SUBJECT: Brake Grind Or Growl Sound MODELS: 1998 - 1999 (DN) Durango SYMPTOM/CONDITION: Brake grind or growl sound coming from the front brakes during low speed braking (less than five mph (eight kph)). These sounds will usually be heard during light to moderate brake applications and from speeds from zero to five (5) miles per hour (8 kph). During braking, these sounds will be characterized by: ^ Growl/grind noise that may be accompanied by squeal ^ Low frequency grinding noise that may be accompanied by pedal pulsation ^ Steering wheel and seat vibration (in extreme conditions) NOTE: NO REDUCTION IN BRAKING ABILITY OR PARTICULAR DAMAGE TO THE BRAKE SYSTEM WILL RESULT FROM THESE NOISES. DIAGNOSIS: 1. Drive the vehicle on a smooth surfaced road in an area away from heavy traffic and high surrounding noise. 2. Make several stops from a moderate speed to generate some heat within the brake system. 3. Accelerate to 15-20 mph (24-32 kph), then apply moderate pressure to the brake pedal until the vehicle comes to a stop. 4. If a grinding/growling noise is coming from the front brakes perform the Repair Procedure. If there is no noise, drive the vehicle for several miles (kilometers) with minimal brake applications to allow the brake system to cool or park the vehicle until the brakes cool, then repeat Steps 2 and 3 again. If the grinding/growling noise is now coming from the front brakes, perform the Repair Procedure. PARTS REQUIRED: 1 05014095AB Kit, Front Brake Shoe AR (2) 52009208 Rotor, Brake POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-70-22-92 Replace Front Disc Brake Shoes 0.8 Hrs. Relate Operation No: 05-21-10-50 Replace Disc Brake Rotor, Right Side 0.1 Hrs. 05-21-10-51 Replace Disc Brake Rotor, Left Side 0.1 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest for Brake Rotor/Disc: > 05-05-98 > Oct > 98 > Front Brakes Grind or Growl Sound > Page 4136 Repair Procedure This bulletin involves installing a revised set of front brake shoes. 1. Clean master cylinder reservoir and filler caps. 2. Remove the reservoir filler cap and remove approximately 1/4 of the fluid from the reservoir. Use a clean suction gun or similar device to drain the brake fluid. 3. Raise and support the vehicle. 4. Remove front wheel and tire assemblies. 5. Bottom the caliper pistons in the caliper bores using a large C-clamp. Position the C-clamp frame on the rear of the caliper and clamp screw on the outboard brake shoe. 6. Remove the caliper slide pins. 7. Remove caliper from caliper adapter. CAUTION: DO NOT ALLOW THE CALIPER TO HANG BY THE BRAKE HOSE. USE A HANGER TO SUPPORT THE CALIPER WHILE SERVICING THE BRAKE SHOES. 8. Remove the outboard brake shoe (Figure 1). Pry one end of the shoe retainer spring away from the caliper, then tilt the shoe upward and rotate it out of the caliper. 9. Remove the inboard brake shoe by tilting the shoe outward until the retainer spring is clear of the caliper piston (Figure 2). 10. Remove any dirt or foreign material from the wear surface of the rotor. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest for Brake Rotor/Disc: > 05-05-98 > Oct > 98 > Front Brakes Grind or Growl Sound > Page 4137 11. Secure a dial indicator onto the steering knuckle so that the plunger of the dial indicator is positioned approximately 25.4 mm (1 in.) inward from the rotor's edge (Figure 3). If the runout exceeds 0.102 mm (0.004 in.), replace the rotor with p/n 52009208. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), page 5-16 for information regarding rotor replacement. 12. Position a micrometer approximately 25.4 mm (1 in.) from the rotor outer circumference (Figure 4) and measure the rotor thickness. Take an additional 6-12 measurements around the rotor. If the thickness of the rotor varies more than 0.013 mm (0.0005 in.) from point to point, replace the rotor with p/n 52009208. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), page 5-16 for information regarding rotor replacement. 13. Install inboard brake shoe from brake shoe kit p/n 05014095AB. Be sure the retainer spring is firmly seated in the caliper piston. 14. Insert outboard brake shoe into the caliper (Figure 5). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest for Brake Rotor/Disc: > 05-05-98 > Oct > 98 > Front Brakes Grind or Growl Sound > Page 4138 15. Ensure the outboard brake shoe retainer springs are seated in the caliper (Figure 6). 16. Install caliper and brake shoe assembly over the rotor and into the adapter. Be sure the brake shoe tangs are properly seated on the adapter ledges. 17. Install and tighten the caliper slide pins to 25-35 N.m (18-26 ft. lbs.). NOTE: START THE SLIDE PINS BY HAND BEFORE TIGHTENING. DO NOT CROSS THREAD THE PINS. 18. Perform Steps 5 through 17 to the front brakes on the other side of the vehicle. 19. Install the wheel and tire assembly. 20. Remove supports and lower the vehicle. 21. Pump the brake pedal several times to seat the new brake shoes. CAUTION: VERIFY A FIRM BRAKE PEDAL BEFORE MOVING THE VEHICLE. 22. Ensure that the master cylinder reservoir is at the proper level as indicated on the side of the reservoir. Fill the reservoir with Mopar Brake Fluid p/n 04318080. 23. Repeat the Diagnosis to ensure that the brake growl/grind noise has been eliminated. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 05-05-98 > Oct > 98 > Front Brakes - Grind or Growl Sound Technical Service Bulletin # 05-05-98 Date: 981009 Front Brakes - Grind or Growl Sound NO: 05-05-98 GROUP: Brakes DATE: Oct. 9, 1998 SUBJECT: Brake Grind Or Growl Sound MODELS: 1998 - 1999 (DN) Durango SYMPTOM/CONDITION: Brake grind or growl sound coming from the front brakes during low speed braking (less than five mph (eight kph)). These sounds will usually be heard during light to moderate brake applications and from speeds from zero to five (5) miles per hour (8 kph). During braking, these sounds will be characterized by: ^ Growl/grind noise that may be accompanied by squeal ^ Low frequency grinding noise that may be accompanied by pedal pulsation ^ Steering wheel and seat vibration (in extreme conditions) NOTE: NO REDUCTION IN BRAKING ABILITY OR PARTICULAR DAMAGE TO THE BRAKE SYSTEM WILL RESULT FROM THESE NOISES. DIAGNOSIS: 1. Drive the vehicle on a smooth surfaced road in an area away from heavy traffic and high surrounding noise. 2. Make several stops from a moderate speed to generate some heat within the brake system. 3. Accelerate to 15-20 mph (24-32 kph), then apply moderate pressure to the brake pedal until the vehicle comes to a stop. 4. If a grinding/growling noise is coming from the front brakes perform the Repair Procedure. If there is no noise, drive the vehicle for several miles (kilometers) with minimal brake applications to allow the brake system to cool or park the vehicle until the brakes cool, then repeat Steps 2 and 3 again. If the grinding/growling noise is now coming from the front brakes, perform the Repair Procedure. PARTS REQUIRED: 1 05014095AB Kit, Front Brake Shoe AR (2) 52009208 Rotor, Brake POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-70-22-92 Replace Front Disc Brake Shoes 0.8 Hrs. Relate Operation No: 05-21-10-50 Replace Disc Brake Rotor, Right Side 0.1 Hrs. 05-21-10-51 Replace Disc Brake Rotor, Left Side 0.1 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 05-05-98 > Oct > 98 > Front Brakes - Grind or Growl Sound > Page 4144 Repair Procedure This bulletin involves installing a revised set of front brake shoes. 1. Clean master cylinder reservoir and filler caps. 2. Remove the reservoir filler cap and remove approximately 1/4 of the fluid from the reservoir. Use a clean suction gun or similar device to drain the brake fluid. 3. Raise and support the vehicle. 4. Remove front wheel and tire assemblies. 5. Bottom the caliper pistons in the caliper bores using a large C-clamp. Position the C-clamp frame on the rear of the caliper and clamp screw on the outboard brake shoe. 6. Remove the caliper slide pins. 7. Remove caliper from caliper adapter. CAUTION: DO NOT ALLOW THE CALIPER TO HANG BY THE BRAKE HOSE. USE A HANGER TO SUPPORT THE CALIPER WHILE SERVICING THE BRAKE SHOES. 8. Remove the outboard brake shoe (Figure 1). Pry one end of the shoe retainer spring away from the caliper, then tilt the shoe upward and rotate it out of the caliper. 9. Remove the inboard brake shoe by tilting the shoe outward until the retainer spring is clear of the caliper piston (Figure 2). 10. Remove any dirt or foreign material from the wear surface of the rotor. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 05-05-98 > Oct > 98 > Front Brakes - Grind or Growl Sound > Page 4145 11. Secure a dial indicator onto the steering knuckle so that the plunger of the dial indicator is positioned approximately 25.4 mm (1 in.) inward from the rotor's edge (Figure 3). If the runout exceeds 0.102 mm (0.004 in.), replace the rotor with p/n 52009208. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), page 5-16 for information regarding rotor replacement. 12. Position a micrometer approximately 25.4 mm (1 in.) from the rotor outer circumference (Figure 4) and measure the rotor thickness. Take an additional 6-12 measurements around the rotor. If the thickness of the rotor varies more than 0.013 mm (0.0005 in.) from point to point, replace the rotor with p/n 52009208. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), page 5-16 for information regarding rotor replacement. 13. Install inboard brake shoe from brake shoe kit p/n 05014095AB. Be sure the retainer spring is firmly seated in the caliper piston. 14. Insert outboard brake shoe into the caliper (Figure 5). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 05-05-98 > Oct > 98 > Front Brakes - Grind or Growl Sound > Page 4146 15. Ensure the outboard brake shoe retainer springs are seated in the caliper (Figure 6). 16. Install caliper and brake shoe assembly over the rotor and into the adapter. Be sure the brake shoe tangs are properly seated on the adapter ledges. 17. Install and tighten the caliper slide pins to 25-35 N.m (18-26 ft. lbs.). NOTE: START THE SLIDE PINS BY HAND BEFORE TIGHTENING. DO NOT CROSS THREAD THE PINS. 18. Perform Steps 5 through 17 to the front brakes on the other side of the vehicle. 19. Install the wheel and tire assembly. 20. Remove supports and lower the vehicle. 21. Pump the brake pedal several times to seat the new brake shoes. CAUTION: VERIFY A FIRM BRAKE PEDAL BEFORE MOVING THE VEHICLE. 22. Ensure that the master cylinder reservoir is at the proper level as indicated on the side of the reservoir. Fill the reservoir with Mopar Brake Fluid p/n 04318080. 23. Repeat the Diagnosis to ensure that the brake growl/grind noise has been eliminated. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 4147 Brake Rotor/Disc: Specifications Front Rotor Specifications: Nominal Thickness .............................................................................................................................. .............................................................. 0.949" Minimum Machine Thickness .............................................................................................................. ...................................................................... * Discard Thickness ............................................................................................................................... .............................................................. 0.890" Runout Limit ........................................................................................................................................ ............................................................. 0.004" Maximum Parallel Variation ................................................................................................................. .......................................................... 0.0005" * - Information not supplied by the manufacturer. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 4148 Brake Rotor/Disc: Testing and Inspection 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 Checking Rotor Runout And Thickness Variation 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 4149 Measuring Rotor Thickness Measure rotor thickness at 6 to 12 points around the rotor face. Position the micrometer approximately 25.4 mm (1 inch) from 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Rotor Removal and Installation Brake Rotor/Disc: Service and Repair Rotor Removal and Installation REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper. 4. Remove retainers on wheel studs and remove rotor. INSTALLATION 1. Install rotor hub and install retainers. 2. Install brake caliper. 3. Install wheel and tire assembly. 4. Remove support and lower vehicle. 5. Depress brake pedal several time to seat brake shoes. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Rotor Removal and Installation > Page 4152 Brake Rotor/Disc: Service and Repair Rotor Refinishing 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. Equipment capable of machining only one side at a time may produce a tapered rotor. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications Backing Plate: Specifications Mounting Bolts/Nuts ............................................................................................................................ .................................................... 64 Nm (47 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 4157 Backing Plate: Service and Repair REMOVAL 1. Remove wheel and tire assembly and brake drum. 2. Remove brake shoe assembly. 3. Remove parking brake cable from parking brake lever. 4. Compress parking brake cable retainer tabs. Then push retainer and cable through and out of support plate. 5. Disconnect brake line at wheel cylinder. 6. Remove wheel cylinder from support plate. 7. Remove axle shaft. 8. Remove bolts attaching support plate to axle and remove support plate. INSTALLATION 1. Apply bead of silicone sealer around axle mounting surface of support plate. 2. Install support plate on axle flange. Tighten attaching bolts to 115 Nm (85 ft. lbs.). 3. Apply bead of silicone sealer around wheel cylinder mounting surface and install wheel cylinder. 4. Install brake line in wheel cylinder. 5. Install parking brake cable in support plate. 6. Install axle shaft. 7. Connect parking brake cable to lever on secondary shoe and install brake shoes on support plate. 8. Adjust brake shoes to drum with brake gauge. 9. Install brake drum and wheel and tire assembly. 10. Bleed brake system. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 4161 Brake Drum: Testing and Inspection 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Refinishing Brake Drum: Service and Repair Brake Drum Refinishing 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Refinishing > Page 4164 Brake Drum: Service and Repair Cleaning and Inspection CLEANING Clean the individual brake components, including the support plate and wheel cylinder exterior, with a water dampened cloth or with brake cleaner. Do not use any other cleaning agents. Remove light rust and scale from the brake shoe contact pads on the support plate with fine sandpaper. INSPECTION 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 lining should be replaced when worn to a thickness of 1.6 mm (1/16 inch). Examine the lining contact pattern to determine if the shoes are bent or the drum is tapered. The lining should exhibit contact across its entire width. Shoes exhibiting contact only on one side should be replaced and the drum checked for runout or taper. Inspect the adjuster screw assembly. Replace the assembly if the star wheel or threads are damaged, or the components are severely rusted or corroded. Discard the brake springs and retainer components if worn, distorted or collapsed. Also replace the springs if a brake drag condition had occurred. Overheating will distort and weaken the springs. Inspect the brake shoe contact pads on the support plate, replace the support plate if any of the pads are worn or rusted through. Also replace the plate if it is bent or distorted. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4168 Brake Shoe: Service and Repair REMOVAL 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4169 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 1. Clean and inspect individual brake components. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4170 8. Install secondary shoe on support plate. Insert strut in shoe and guide shoe onto anchor pin. Temporarily secure shoe with retaining Din. 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Mounting Bolts 15 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation Wheel Cylinder: Service and Repair Wheel Cylinder 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 cylinder mounting surface of support plate. 2. Install cylinder mounting bolts and tighten to 20 Nm (15 ft. lbs.). 3. Connect brake line to cylinder. 4. Install brake shoe return spring. 5. Install brake drum. 6. Install wheel and tire assembly. 7. Bleed base brake system. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4176 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4177 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul DISASSEMBLY 1. Remove push rods and boots. 2. Press pistons, cups and spring and expander out of cylinder bore. 3. Remove bleed 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures W/ Four Wheel Antilock Brakes ABS system bleeding requires conventional bleeding methods plus use of the DRB scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. W/ Rear Wheel Antilock Brakes 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. Do not pump the brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles that are distributed throughout the hydraulic system. This will make additional bleeding operations necessary. Do not allow the master cylinder to run out of fluid during bleed operations. An empty cylinder will allow additional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed. Bleed only one brake component at a time in the following sequence: Master Cylinder - Combination Valve - Rear Antilock Valve - Left Rear Wheel - Right Rear Wheel - Right Front Wheel - Left Front Wheel MANUAL BLEEDING 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. Bleed Hose Setup 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 4183 PRESSURE BLEEDING 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 the adapter provided with the equipment or Adapter 6921. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 4184 Brake Bleeding: Service and Repair Base Brake System 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. Do not pump the brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles that are distributed throughout the hydraulic system. This will make additional bleeding operations necessary. Do not allow the master cylinder to run out of fluid during bleed operations. An empty cylinder will allow additional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed. Bleed only one brake component at a time in the following sequence: Master Cylinder - Combination Valve - Rear Antilock Valve - Right Rear Wheel - Left Rear Wheel - Right Front Wheel - Left Front Wheel MANUAL BLEEDING 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. Bleed Hose Setup 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. PRESSURE BLEEDING 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair Brake Caliper: Technical Service Bulletins Front Caliper Mounting/Steering Knuckle - Thread Repair NUMBER: 05-03-99 GROUP: Brakes EFFECTIVE DATE: Apr. 23, 1999 SUBJECT: Front Brake Caliper Mounting To Steering Knuckle Thread Repair OVERVIEW: This bulletin involves repair of the threads on the steering knuckle or brake caliper mounting adapter that are used to install and retain the front brake caliper housing in its correct operating location. MODELS: 1986 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango DISCUSSION: A Brake Knuckle Thread Repair Kit has been developed to repair stripped threads on the front brake caliper mounting attachment making it no longer necessary to replace the front steering knuckle/brake caliper mounting adapter when encountering stripped threads. The following information provides the repair procedure for using the Brake Knuckle Thread Repair Kit. DIAGNOSIS: 1. Place the vehicle on an appropriate hoist. 2. Remove the front tire/wheel assembly. 3. Remove the brake caliper housing assembly by loosening the mounting bolts. NOTE: IF HIGH TORQUE IS ENCOUNTERED DURING THE MOUNTING BOLT REMOVAL, IT IS LIKELY THAT THREAD DAMAGE WILL OCCUR OR HAS OCCURRED. 4. Remove the caliper housing assembly and hang the housing on the frame of the vehicle using an appropriate wire hanger. NOTE: DO NOT ALLOW THE CALIPER HOUSING TO HANG BY ITSELF FROM THE BRAKE HOSE AS DAMAGE TO THE HOSE MAY RESULT. 5. If the vehicle has a bolt-on brake caliper mounting adapter, remove the adapter. If the brake caliper mounts directly to the steering knuckle, remove retainers on the wheel studs and remove the rotor. 6. Inspect the mounting bolts and knuckle threads for damage. If either is damaged, it is likely that damage to the other has occurred as well. If damage has occurred to the threads in the form of knicks, thread pulling, or cross-threading, perform the Repair Procedure. PARTS REQUIRED: AR (1) 05016156AA Insert, Heli-Coil, M9 X 1.25 AR (1) 04886075AA Bolts, Caliper Housing Mounting EQUIPMENT REQUIRED: AR (1) 05016155AA Kit, Brake Knuckle Thread Repair Includes: 23/64 Drill Bit M9 X 1.25 Tap Heli-Coil Installation Tool Heli-Coil Tang Break-Off Rod (25) M9 X 1.25 Stainless Steel Heli-Coils REPAIR PROCEDURE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair > Page 4189 1. Using the 23/64 in. drill, drill through the brake caliper mounting attachment hole keeping the drill perpendicular to the knuckle. 2. Using the M9 X 1.25 tap, tap the drilled hole ensuring to tap the hole entirely through. 3. Install a Heli-Coil insert onto the installation tool (tool number 3747-9). Be sure the tang is properly engaged into the driving contour of the tool. 4. Install the Heli-Coil into the drilled/tapped hole by rotating the tool and exerting slight pressure onto the tool/Heli-Coil and into the drilled/tapped hole. Continue to rotate the tool until the insert is located 1/4 to 1/2 turn below the steering knuckle surface. 5. Back the Heli-Coil installation tool out of the installed Heli-Coil. Then, remove the tang from the Heli-Coil by breaking the tang off using the tang break-off tool. Place the break-off tool into the assembled insert until it rests on the Heli-Coil tang. Holding the tool squarely, strike the tool sharply with a hammer. 6. If the vehicle has a bolt-on brake caliper mounting adapter, install the adapter. Refer to the appropriate Service Manual for information regarding proper brake caliper adapter mounting information. If the brake caliper mounts directly to the steering knuckle, install the rotor. 7. Install the caliper using new mounting bolts p/n 04886075AA in any location that had a Heli-Coil installed. Tighten the bolts to 30 - 35 N.m (22-26 ft. lbs.). 8. Install the tire/wheel assembly. 9. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-93 Brake Caliper Mounting Support Thread Repair, Left Side 0.4 Hrs. 05-80-20-94 Brake Caliper Mounting Support Thread Repair, Right Side 0.4 Hrs. 05-80-20-50 Brake Caliper Mounting Support Thread Repair, Each Additional Same Side 0.1 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Page 4190 Brake Caliper: Specifications Bore 2.75 in Mounting Bolts 22 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation REMOVAL 1. Raise and support vehicle. 2. Remove front wheel and tire assemblies. Caliper Brake Hose Connection 3. Disconnect brake hose at caliper. Discard hose fitting washers if worn, or damaged. 4. Remove caliper slide pins. 5. Remove caliper and brake shoes from caliper. INSTALLATION 1. Install brake shoes in caliper. 2. Install 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. Align caliper in adapter and install caliper slide pins. Tighten caliper slide pins to 30 Nm (22 ft. lbs.). 4. Install brake hose to 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. 5. Bleed base brake system. 6. Install wheel and tire assemblies. 7. Remove supports and lower vehicle. 8. Verify firm pedal before moving vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4193 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. Caliper Piston Removal 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 pressure to ease the piston out. WARNING: NEVER ATTEMPT TO CATCH THE PISTON AS IT LEAVES THE BORE. THIS MAY RESULT IN PERSONAL INJURY. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4194 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. Sliding Boot Onto Piston Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4195 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4196 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4197 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, 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 interchange 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4201 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4202 Brake Fluid: Testing and Inspection CAUTION: The hydraulic fluid used in automotive brake systems is hygroscopic. This means that the hydraulic fluid tends to absorb moisture from the atmosphere over periods of time. As hydraulic brake fluid absorbs moisture, it effects the function of the vehicles hydraulic brake system. For this reason, the vehicle's hydraulic brake fluid should be drained and replaced using fresh clean hydraulic brake fluid every two years. When replacing hydraulic brake fluid, use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications. BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates 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 the fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber parts or components containing rubber coming into contact with the brake fluid. This includes the master cylinder, proportioning valves, caliper seals, wheel cylinder seals, ABS hydraulic control unit (HCU), and all hydraulic fluid hoses. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4203 Brake Fluid: Service and Repair Always clean the master cylinder reservoir and caps before checking fluid level. If not cleaned, dirt could enter the fluid. Brake Fluid Level Inspection The fluid fill level is indicated on the side of the master cylinder reservoir. The correct fluid level is to the FULL indicator on the side of the reservoir. If necessary, add fluid to the proper level. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Locations Brake Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 4207 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 4208 Brake Fluid Pressure Sensor/Switch: Testing and Inspection PRESSURE DIFFERENTIAL SWITCH 1. Have 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 841 > Feb > 00 > Recall - Fuel Tank Straps and Rear Brake Tube Brake Hose/Line: Recalls Recall - Fuel Tank Straps and Rear Brake Tube NO 841 DATE 02/17/00 SAFETY RECALL 841 Fuel Tank Straps and Rear Brake Tube MODELS 1998 ,(DN) Dodge Durango ATTENTION: Service Manager RECALL MATERIAL ENCLOSED IMMEDIATE ACTION REQUIRED The envelope contains one copy of the dealer recall service instruction letter. In addition, a VIN listing is included for those dealers to whom involved vehicles were invoiced. The owner notification mailing for this recall will begin in about one week. Please advise the appropriate dealer personnel to forward the orange bordered recall envelope to your service manager as soon as it is received. Doing so will insure that our dealership is ready to schedule and repair involved vehicles soon as possible. Additional copies of the recall notification letter will be forwarded via DCMMS mail and the MDS2 in the near future. The entire dealer recall notification letter (excluding graphics) is provided below for your information. February 2000 Dealer Service Instructions for: SAFETY RECALL No. 841 FUEL TANK STRAPS AND REAR BRAKE TUBE. NOTE: This recall applies only to the above vehicles built through May 21, 1998 (MDH 0521XX). NOTE: Safety Recall No. 842 also involves fuel tank strap replacement but applies to later built vehicles that do not require the brake tube inspection. ATTENTION: Service Manager Recall material enclosed immediate action required require the brake tube inspection. 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 DIAL VIP System. SUBJECT The fuel tank straps on about 96,OOO of the above vehicles may fatigue and separate. If this occurs, the fuel tank will loosen and could leak fuel. Fuel leakage in the presence of an ignition source can result in an underbody fire. In addition, the rear brake tube may contact an underbody crossmember. Prolonged brake tube contact may cause the tube to rub through and leak, resulting in a partial brake system loss and increased stopping distance. The increased stopping distance can cause an accident without warning. REPAIR The front and rear fuel tank straps must be replaced, and the rear brake tube must be inspected on all involved vehicles. ~7ehicles without brake tube contact must have a brake tube isolator installed. Vehicles that exhibit contact but have no signs of red rust AND have less than 45,000 miles must have an isolator installed with RTV silicone. Vehicles that exhibit contact and have red rust OR have more than 45,000 miles must have a new brake tube and isolator installed. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 841 > Feb > 00 > Recall - Fuel Tank Straps and Rear Brake Tube > Page 4217 Parts Information Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Fuel Tank Strap Packages to service about 25% of those vehicles. In addition, each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive ONE (1) Rear Brake Tube, PN 52102243AC. Additional brake tubes should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require rear brake tube replacement. SERVICE PROCEDURE A. Inspect Rear Brake Tube: 1. Raise the vehicle on an appropriate hoist. 2. For vehicles equipped with a fuel tank skid plate: a. Place a transmission jack under the fuel tank skid plate and support the skid plate. b. Remove the inboard screws that attach the skid plate to the frame crossmember (Figure 1) c. Remove the bolts that attach the skid plate to the frame rail (Figure 1). d. Lower the skid plate and remove it from under the vehicle. 3. Remove the three (3) bolts that attach the evaporative canister bracket to the fraim rail and body. set the evaporative canister aside. 4. Using a mirror and flashlight, inspect the top of the rear brake tube where it is routed near the body crossmember just above the front of the fuel tank (Figure 2). 5. If there is evidence of brake tube contact and there is red rust on the brake tube, the brake tube must be replaced. Continue with Section "C" - Replace Fuel Tank Straps and Rear Brake Tube. Tubes with white powder or other residue/discoloration do not require replacement. If there is evidence of contact with NO RED RUST on the brake tube but the vehicle has MORE than 45,000 miles, the brake tube must be replaced. Continue with Section "C" - Replace Fuel Tank Straps and Rear Brake Tube. If there is evidence of contact with no red rust on the brake tube but the vehicle has less than 45,000 miles, the brake tube does NOT require replacement. Continue with Section "B" - Replace Fuel Tank Straps and Install Isolator. If there is no evidence of brake tube contact, the brake tube does not require replacement. continue with section "B" - replace fuel tank straps and install isolator. B. Replace Fuel Tank Straps and Install Isolator: 1. Clean the area of the brake tube shown in Figure 3 with Brake Clean, PN 04897150AA. 2. If the inspection in Section "A" determined that there was brake tube contact with the body crossmember and there was no red rust, coat the brake tube contact area with RTV Sealant (Mopar PN 82300234 or equivalent). 3. Fill the cavity of the provided brake tube rubber isolator with RTV Sealant (Mopar PN 82300234 or equivalent). 4. Snap the isolator over the brake tube. Center the isolator over the area of the tube that is closest to the body crossmember (Figure 3). Position the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 841 > Feb > 00 > Recall - Fuel Tank Straps and Rear Brake Tube > Page 4218 isolator with the slit toward the ground. NOTE: It is acceptable, and likely, that the rubber isolator will be in contact with the body crossmember. Do NOT bend the brake tube to avoid contact with the body crossmember. 5. Place a transmission jack under the fuel tank and support the fuel tank. 6. Remove the front tank strap mounting nut and remove the front tank strap (Figure 4). NOTE: Lower the fuel tank slightly to ease removal of the strap. 7. Install the provided front tank strap (Figure 4). Tighten the strap mounting nut to 30 ft-lbs (41 Nm). 8. Remove the rear tank strap mounting nut and remove the rear tank strap (Figure 2). NOTE: Lower the fuel tank slightly to ease removal of the strap. 9. Install the provided rear tank strap (Figure 2). Tighten the strap mounting nut to 30 ft-lbs (41 Nm). 10. Remove the transmission jack. 11. Install the evaporative canister and bracket assembly. Tighten the three (3) bolts that attach the evaporative canister bracket to the frame rail and body to 90 in-lbs (10 Nm). 12. For vehicles equipped with a fuel tank skid plate: a. Position the skid plate under the vehicle and support it with a transmission jack. b. Install the inboard screws that attach the skid plate to the frame crossmember (Figure 1). Tighten the screws to 30 ft-lbs (41 Nm) c. Install the bolts that attach the skid plate to the frame rail (Figure 1). Tighten the bolts to 17 ft-lbs (23 Nm). d. Remove the transmission jack. 13. Lower the vehicle. C. Replace Fuel Tank Straps and Rear Brake Tube: NOTE: Only those vehicles that have damaged brake tubes, as determined by the inspection in Section "A", require replacement. Very few vehicles are expected to require brake tube replacement. 1. Lower vehicle. Depress and hold the brake pedal using a brake pedal prop rod. NOTE: Keeping the brake pedal in the "applied" position makes bleeding the brakes faster and easier since only the rear brakes will require bleeding. 3. Raise vehicle on hoist. 4. Disconnect the fuel tank fuel filler vent hose from the vent tube. Do not disconnect vent hose from fuel tank. 5. Insert a siphon hose through the~ vent hose and drain the fuel into an approved gasoline container. 6. Place a transmission jack under the fuel tank and support the fuel tank. 7. Remove the front tank strap mounting nut, then remove and discard the front tank strap (Figure 5). NOTE: Lower the fuel tank slightly to ease removal of the straps. 8. Remove the rear tank strap mounting nut, then remove and discard the rear tank strap (Figure 5). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 841 > Feb > 00 > Recall - Fuel Tank Straps and Rear Brake Tube > Page 4219 9. Lower the fuel tank approximately six inches (6") and move it inboard to allow access to the rear brake tube. 10. Disconnect the rear brake tube from the junction block at the front of the vehicle. 11. Remove the rear brake tube from the clips along the frame rail. 12. Disconnect the rear brake tube from the rear brake hose. 13. Remove and discard the rear brake tube by sliding it forward. 14. Install the new brake tube along the frame rail. Make sure that the tube is routed behind the evaporative canister lines and above the fuel tube. 15. Connect the brake tube to the brake hose. Tighten the fitting to 170 in-lbs (19 Nm) 16. Connect the brake tube to the junction block at the front of the vehicle. Tighten the fitting to 145 in-lbs (16 Nm) 17. Clean the area of the brake tube shown in Figure 6 with Brake Clean, PN 04897150AA. 18. Install the brake tube into the clips along the frame rail. 19. Fill the cavity of the provided brake tube isolator with RTV Sealant (Mopar PN 82300234 or equivalent). 20. Snap the isolator over the brake tube. Center the isolator over the area of the tube that is closest to the body crossmember (Figure 6). Position the isolator with the slit toward the ground. NOTE: It is acceptable, and likely, that the rubber isolator will be in contact with the body crossmember. Do NOT bend the brake tube to avoid contact with the body crossmember. 21. Raise the fuel tank into position. 22. Install the provided front tank strap (Figure 5). Tighten the strap mounting nut to 30 ft-lbs (41 Nm). 23. Install the provided rear tank strap (Figure 5). Tighten the strap mounting nut to 30 ft-lbs (41 Nm) 24. Connect the fuel vent hose to the vent tube. Tighten the hose clamp to 25 in-lbs (3 Nm) 25. Bleed both rear brake circuits as follows: a. Fill the master cylinder reservoir with clean brake fluid that conforms to DOT-3 specifications. b. Attach a clear plastic hose to both rear bleeder screws and feed the hoses into a clear jar containing enough fresh brake fluid to submerge the end of the hose. c. Have a helper pump the brake pedal three or four times and then hold it in the down position. d. With the pedal in the down position, open the right bleeder screw at least one full turn. e. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. f. Alternating between the right and left side, repeat steps "C" through "E" until all trapped air is removed from the rear brake circuits (usually four or five times). 26. Top off the master cylinder, then inspect the brake tube connections to ensure that there are no leaks. 27. Install the evaporative canister and bracket assembly. Tighten the three (3) bolts that attach the evaporative canister bracket to the frame rail and body to 90 in-lbs (10 Nm). 28. For vehicles equipped with a fuel tank skid plate: a. Position the skid plate under the vehicle and support it with a transmission jack. b. Install the inboard screws that attach the skid plate to the frame crossmember (Figure 1). Tighten the screws to 30 ft-lbs (41 Nm) c. Install the bolts that attach the skid plate to the frame rail (Figure 1). Tighten the bolts to 17 ft-lbs (23 Nm) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 841 > Feb > 00 > Recall - Fuel Tank Straps and Rear Brake Tube > Page 4220 d. Remove the transmission jack. 29. Lower the vehicle. 30. Refill the fuel tank and ensure that there are no leaks. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time Allowances Add the cost of the recall parts package and brake tube, if necessary, plus applicable dealer allowance to your claim. NOTE: See the warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return: Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MD52 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION1' prompt, then type 110RD84111. 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 copy of the owner notification letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 841 > Feb > 00 > Recall - Fuel Tank Straps and Rear Brake Tube > Page 4221 DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 841 > Feb > 00 > Recall Fuel Tank Straps and Rear Brake Tube Brake Hose/Line: All Technical Service Bulletins Recall - Fuel Tank Straps and Rear Brake Tube NO 841 DATE 02/17/00 SAFETY RECALL 841 Fuel Tank Straps and Rear Brake Tube MODELS 1998 ,(DN) Dodge Durango ATTENTION: Service Manager RECALL MATERIAL ENCLOSED IMMEDIATE ACTION REQUIRED The envelope contains one copy of the dealer recall service instruction letter. In addition, a VIN listing is included for those dealers to whom involved vehicles were invoiced. The owner notification mailing for this recall will begin in about one week. Please advise the appropriate dealer personnel to forward the orange bordered recall envelope to your service manager as soon as it is received. Doing so will insure that our dealership is ready to schedule and repair involved vehicles soon as possible. Additional copies of the recall notification letter will be forwarded via DCMMS mail and the MDS2 in the near future. The entire dealer recall notification letter (excluding graphics) is provided below for your information. February 2000 Dealer Service Instructions for: SAFETY RECALL No. 841 FUEL TANK STRAPS AND REAR BRAKE TUBE. NOTE: This recall applies only to the above vehicles built through May 21, 1998 (MDH 0521XX). NOTE: Safety Recall No. 842 also involves fuel tank strap replacement but applies to later built vehicles that do not require the brake tube inspection. ATTENTION: Service Manager Recall material enclosed immediate action required require the brake tube inspection. 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 DIAL VIP System. SUBJECT The fuel tank straps on about 96,OOO of the above vehicles may fatigue and separate. If this occurs, the fuel tank will loosen and could leak fuel. Fuel leakage in the presence of an ignition source can result in an underbody fire. In addition, the rear brake tube may contact an underbody crossmember. Prolonged brake tube contact may cause the tube to rub through and leak, resulting in a partial brake system loss and increased stopping distance. The increased stopping distance can cause an accident without warning. REPAIR The front and rear fuel tank straps must be replaced, and the rear brake tube must be inspected on all involved vehicles. ~7ehicles without brake tube contact must have a brake tube isolator installed. Vehicles that exhibit contact but have no signs of red rust AND have less than 45,000 miles must have an isolator installed with RTV silicone. Vehicles that exhibit contact and have red rust OR have more than 45,000 miles must have a new brake tube and isolator installed. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 841 > Feb > 00 > Recall Fuel Tank Straps and Rear Brake Tube > Page 4227 Parts Information Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Fuel Tank Strap Packages to service about 25% of those vehicles. In addition, each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive ONE (1) Rear Brake Tube, PN 52102243AC. Additional brake tubes should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require rear brake tube replacement. SERVICE PROCEDURE A. Inspect Rear Brake Tube: 1. Raise the vehicle on an appropriate hoist. 2. For vehicles equipped with a fuel tank skid plate: a. Place a transmission jack under the fuel tank skid plate and support the skid plate. b. Remove the inboard screws that attach the skid plate to the frame crossmember (Figure 1) c. Remove the bolts that attach the skid plate to the frame rail (Figure 1). d. Lower the skid plate and remove it from under the vehicle. 3. Remove the three (3) bolts that attach the evaporative canister bracket to the fraim rail and body. set the evaporative canister aside. 4. Using a mirror and flashlight, inspect the top of the rear brake tube where it is routed near the body crossmember just above the front of the fuel tank (Figure 2). 5. If there is evidence of brake tube contact and there is red rust on the brake tube, the brake tube must be replaced. Continue with Section "C" - Replace Fuel Tank Straps and Rear Brake Tube. Tubes with white powder or other residue/discoloration do not require replacement. If there is evidence of contact with NO RED RUST on the brake tube but the vehicle has MORE than 45,000 miles, the brake tube must be replaced. Continue with Section "C" - Replace Fuel Tank Straps and Rear Brake Tube. If there is evidence of contact with no red rust on the brake tube but the vehicle has less than 45,000 miles, the brake tube does NOT require replacement. Continue with Section "B" - Replace Fuel Tank Straps and Install Isolator. If there is no evidence of brake tube contact, the brake tube does not require replacement. continue with section "B" - replace fuel tank straps and install isolator. B. Replace Fuel Tank Straps and Install Isolator: 1. Clean the area of the brake tube shown in Figure 3 with Brake Clean, PN 04897150AA. 2. If the inspection in Section "A" determined that there was brake tube contact with the body crossmember and there was no red rust, coat the brake tube contact area with RTV Sealant (Mopar PN 82300234 or equivalent). 3. Fill the cavity of the provided brake tube rubber isolator with RTV Sealant (Mopar PN 82300234 or equivalent). 4. Snap the isolator over the brake tube. Center the isolator over the area of the tube that is closest to the body crossmember (Figure 3). Position the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 841 > Feb > 00 > Recall Fuel Tank Straps and Rear Brake Tube > Page 4228 isolator with the slit toward the ground. NOTE: It is acceptable, and likely, that the rubber isolator will be in contact with the body crossmember. Do NOT bend the brake tube to avoid contact with the body crossmember. 5. Place a transmission jack under the fuel tank and support the fuel tank. 6. Remove the front tank strap mounting nut and remove the front tank strap (Figure 4). NOTE: Lower the fuel tank slightly to ease removal of the strap. 7. Install the provided front tank strap (Figure 4). Tighten the strap mounting nut to 30 ft-lbs (41 Nm). 8. Remove the rear tank strap mounting nut and remove the rear tank strap (Figure 2). NOTE: Lower the fuel tank slightly to ease removal of the strap. 9. Install the provided rear tank strap (Figure 2). Tighten the strap mounting nut to 30 ft-lbs (41 Nm). 10. Remove the transmission jack. 11. Install the evaporative canister and bracket assembly. Tighten the three (3) bolts that attach the evaporative canister bracket to the frame rail and body to 90 in-lbs (10 Nm). 12. For vehicles equipped with a fuel tank skid plate: a. Position the skid plate under the vehicle and support it with a transmission jack. b. Install the inboard screws that attach the skid plate to the frame crossmember (Figure 1). Tighten the screws to 30 ft-lbs (41 Nm) c. Install the bolts that attach the skid plate to the frame rail (Figure 1). Tighten the bolts to 17 ft-lbs (23 Nm). d. Remove the transmission jack. 13. Lower the vehicle. C. Replace Fuel Tank Straps and Rear Brake Tube: NOTE: Only those vehicles that have damaged brake tubes, as determined by the inspection in Section "A", require replacement. Very few vehicles are expected to require brake tube replacement. 1. Lower vehicle. Depress and hold the brake pedal using a brake pedal prop rod. NOTE: Keeping the brake pedal in the "applied" position makes bleeding the brakes faster and easier since only the rear brakes will require bleeding. 3. Raise vehicle on hoist. 4. Disconnect the fuel tank fuel filler vent hose from the vent tube. Do not disconnect vent hose from fuel tank. 5. Insert a siphon hose through the~ vent hose and drain the fuel into an approved gasoline container. 6. Place a transmission jack under the fuel tank and support the fuel tank. 7. Remove the front tank strap mounting nut, then remove and discard the front tank strap (Figure 5). NOTE: Lower the fuel tank slightly to ease removal of the straps. 8. Remove the rear tank strap mounting nut, then remove and discard the rear tank strap (Figure 5). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 841 > Feb > 00 > Recall Fuel Tank Straps and Rear Brake Tube > Page 4229 9. Lower the fuel tank approximately six inches (6") and move it inboard to allow access to the rear brake tube. 10. Disconnect the rear brake tube from the junction block at the front of the vehicle. 11. Remove the rear brake tube from the clips along the frame rail. 12. Disconnect the rear brake tube from the rear brake hose. 13. Remove and discard the rear brake tube by sliding it forward. 14. Install the new brake tube along the frame rail. Make sure that the tube is routed behind the evaporative canister lines and above the fuel tube. 15. Connect the brake tube to the brake hose. Tighten the fitting to 170 in-lbs (19 Nm) 16. Connect the brake tube to the junction block at the front of the vehicle. Tighten the fitting to 145 in-lbs (16 Nm) 17. Clean the area of the brake tube shown in Figure 6 with Brake Clean, PN 04897150AA. 18. Install the brake tube into the clips along the frame rail. 19. Fill the cavity of the provided brake tube isolator with RTV Sealant (Mopar PN 82300234 or equivalent). 20. Snap the isolator over the brake tube. Center the isolator over the area of the tube that is closest to the body crossmember (Figure 6). Position the isolator with the slit toward the ground. NOTE: It is acceptable, and likely, that the rubber isolator will be in contact with the body crossmember. Do NOT bend the brake tube to avoid contact with the body crossmember. 21. Raise the fuel tank into position. 22. Install the provided front tank strap (Figure 5). Tighten the strap mounting nut to 30 ft-lbs (41 Nm). 23. Install the provided rear tank strap (Figure 5). Tighten the strap mounting nut to 30 ft-lbs (41 Nm) 24. Connect the fuel vent hose to the vent tube. Tighten the hose clamp to 25 in-lbs (3 Nm) 25. Bleed both rear brake circuits as follows: a. Fill the master cylinder reservoir with clean brake fluid that conforms to DOT-3 specifications. b. Attach a clear plastic hose to both rear bleeder screws and feed the hoses into a clear jar containing enough fresh brake fluid to submerge the end of the hose. c. Have a helper pump the brake pedal three or four times and then hold it in the down position. d. With the pedal in the down position, open the right bleeder screw at least one full turn. e. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. f. Alternating between the right and left side, repeat steps "C" through "E" until all trapped air is removed from the rear brake circuits (usually four or five times). 26. Top off the master cylinder, then inspect the brake tube connections to ensure that there are no leaks. 27. Install the evaporative canister and bracket assembly. Tighten the three (3) bolts that attach the evaporative canister bracket to the frame rail and body to 90 in-lbs (10 Nm). 28. For vehicles equipped with a fuel tank skid plate: a. Position the skid plate under the vehicle and support it with a transmission jack. b. Install the inboard screws that attach the skid plate to the frame crossmember (Figure 1). Tighten the screws to 30 ft-lbs (41 Nm) c. Install the bolts that attach the skid plate to the frame rail (Figure 1). Tighten the bolts to 17 ft-lbs (23 Nm) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 841 > Feb > 00 > Recall Fuel Tank Straps and Rear Brake Tube > Page 4230 d. Remove the transmission jack. 29. Lower the vehicle. 30. Refill the fuel tank and ensure that there are no leaks. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time Allowances Add the cost of the recall parts package and brake tube, if necessary, plus applicable dealer allowance to your claim. NOTE: See the warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return: Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MD52 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION1' prompt, then type 110RD84111. 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 copy of the owner notification letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 841 > Feb > 00 > Recall Fuel Tank Straps and Rear Brake Tube > Page 4231 DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Page 4232 Brake Hose/Line: Specifications To Master Cylinder .............................................................................................................................. ............................................... 19 Nm (170 inch lbs.) To Combination Valve ...................................... .................................................................................................................................. 19 Nm (170 inch lbs.) To Wheel Cylinder ....................................................................................................................... ....................................................... 16 Nm (145 inch lbs.) To RWAL Valve ........................................ ......................................................................................................................................... 19 Nm (170 inch lbs.) To ABS Assembly ................................................................................................................ ............................................................... 19 Nm (170 inch lbs.) To Front Fitting ................................. .................................................................................................................................................. 16 Nm (145 inch lbs.) Front Bolt ..................................................................................................................... ....................................................................... 28 Nm (250 inch lbs.) To Rear Fitting .......................... .......................................................................................................................................................... 19 Nm (170 inch lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Page 4233 Brake Hose/Line: Description and Operation 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Page 4234 Brake Hose/Line: Testing and Inspection 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Page 4235 Brake Hose/Line: Service and Repair A pre-formed 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. Inverted Flare And ISO Flare Special bending tools are needed to avoid kinking or twisting of metal brake tubes. Special flaring tools are needed to make a double inverted flare or ISO flare. DOUBLE INVERTED FLARING 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Page 4236 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. ISO FLARING To make an ISO flare use Snap-On Flaring Tool TFM-428 or equivalent. 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 adapter on the flaring tool yoke screw. 6. Lubricate the adapter. 7. Align the adapter and yoke screw over the tube. 8. Turn the yoke screw in until the adapter is squarely seated on the tool bar Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 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. PRESSURE DIFFERENTIAL SWITCH 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. PROPORTIONING VALVE 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%age of rear weight is transferred to the front wheels. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 4240 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications REAR WHEEL ANTILOCK (RWAL) BRAKES: Mounting Bolt ....................................................................................................................................... ................................. 20 - 27 Nm (15 - 20 ft. lbs.) FOUR WHEEL ANTILOCK BRAKES: Bracket Bolts ....................................................................................................................................... ................................... 14 - 15 Nm (10 - 12 ft. lbs.) Mounting Nuts ..................................................... ............................................................................................................................ 12 Nm (102 inch lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Locations > Kelsey-Hayes EBC 2 EBC 2 ABS Components Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Locations > Kelsey-Hayes EBC 2 > Page 4246 EBC 325 ABS Components Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Locations > Page 4247 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > With Four Wheel Antilock Brakes Hydraulic Control Assembly - Antilock Brakes: Description and Operation With Four Wheel Antilock Brakes The Hydraulic Control Unit (HCU) consists of a valve body, pump, two accumulators and a motor. 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. 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 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. 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 wheel speeds. This cycle controls re-application of fluid apply pressure due to changing road surfaces or wheel speed. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > With Four Wheel Antilock Brakes > Page 4250 Hydraulic Control Assembly - Antilock Brakes: Description and Operation With Rear Wheel Antilock Brakes 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Front Antilock Valve Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Front Antilock Valve Replacement NOTE: If the antilock control assembly needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. 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. Mounting Bracket 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Front Antilock Valve Replacement > Page 4253 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Rear Antilock Valve Replacement 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > With Antilock Brakes Brake Master Cylinder: Specifications With Antilock Brakes DIMENSIONS: Bore ..................................................................................................................................................... ............................................... 29 mm (1.125 inch) TIGHTENING TORQUES: Mounting Nuts ..................................................................................................................................... ............................................ 18 Nm (160 inch lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > With Antilock Brakes > Page 4258 Brake Master Cylinder: Specifications Without Antilock Brakes DIMENSIONS: Bore ..................................................................................................................................................... ............................................... 29 mm (1.125 inch) TIGHTENING TORQUES: Mounting Nuts ..................................................................................................................................... ............................................ 18 Nm (160 inch lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4259 Brake Master Cylinder: Description and Operation 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 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4260 Brake Master Cylinder: Testing and Inspection 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 Typical Booster Vacuum Test Connections 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4261 Vacuum Check Valve And Seal 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Brake Master Cylinder: Service and Repair Master Cylinder Bleeding 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. BLEEDING PROCEDURE 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4264 Brake Master Cylinder: Service and Repair Master Cylinder Replacement 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 master cylinder on booster mounting studs. 2. Install mounting nuts and tighten to 18 Nm (160 inch lbs.). 3. Install brake lines and tighten to 19 Nm (170 inch lbs.). 4. Fill and bleed base brake system. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4265 Brake Master Cylinder: Service and Repair Master Cylinder Overhaul REMOVAL 1. Remove reservoir cap and empty fluid into drain container. 2. Clamp cylinder body in vise with brass protective jaws. Brake Fluid Reservoir Retaining Pins 3. Remove pins that retain reservoir to master cylinder. Use hammer and pin punch to remove pins. Loosening Reservoir 4. Loosen reservoir from grommets with pry tool. Brake Fluid Reservoir Removal 5. Remove reservoir by rocking it to one side and pulling free of grommets. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4266 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Mounting Bolts 15 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation Wheel Cylinder: Service and Repair Wheel Cylinder 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 cylinder mounting surface of support plate. 2. Install cylinder mounting bolts and tighten to 20 Nm (15 ft. lbs.). 3. Connect brake line to cylinder. 4. Install brake shoe return spring. 5. Install brake drum. 6. Install wheel and tire assembly. 7. Bleed base brake system. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4272 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4273 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul DISASSEMBLY 1. Remove push rods and boots. 2. Press pistons, cups and spring and expander out of cylinder bore. 3. Remove bleed 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments Parking Brake Cable: 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. Adjustment Mark On Cable Tensioner Rod 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement Parking Brake Cable: Service and Repair Front Cable Replacement REMOVAL 1. Raise and support the vehicle. Cable Tensioner 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 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 4280 Parking Brake Cable: Service and Repair Rear Cable Replacement REMOVAL 1. Raise and support the vehicle. 2. Remove the rear wheel and tire assemblies. 3. Loosen tensioner adjuster nut. Cable Connectors 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. Stabilizer Bar Retainer Cable Retainers Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 4281 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 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 lock 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 it 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Locations Park Brake Release Handle Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Locations > Page 4285 Parking Brake Lever: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Locations > Page 4286 Parking Brake Lever: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 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 firmly 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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. Remove left side kick panel. Parking Brake Pedal Assembly 2. Remove brake release rod from pedal assembly. 3. Disconnect brake warning lamp switch. 4. Remove front parking brake cable. 5. Remove mounting nuts and mounting bolt. 6. Slide assembly rearward off the mounting studs. INSTALLATION 1. Install assembly on the mounting studs. 2. Install mounting bolt and nuts. 3. Install front parking brake cable. 4. Connect brake warning lamp switch. 5. Install brake release rod to pedal assembly. 6. Install left side kick panel. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Mounting Nuts ..................................................................................................................................... ................................................ 28 Nm (250 inch lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4294 Vacuum Brake Booster: Description and Operation All models are equipped with power assist brakes. A tandem diaphragm, power brake booster is used for all applications. The booster unit consists of a single housing divided into chambers 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. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4295 Vacuum Brake Booster: Service and Repair REMOVAL 1. Remove master cylinder. 2. Disconnect vacuum lines at booster. Booster Rod Clip 3. Remove clip securing booster push rod to brake pedal. Power Brake Booster Mounting 4. Remove nuts from booster mounting studs. 5. Remove booster, spacer and gaskets from front cowl panel. INSTALLATION 1. Position spacer and gaskets on booster studs. 2. Guide booster studs into cowl panel holes and seat booster on panel. 3. Install and tighten booster attaching nuts to 28 Nm (250 inch lbs.). 4. Install booster push rod on brake pedal and install clip. 5. Install booster check valve if removed and connect vacuum hose to check valve. 6. Install master cylinder. 7. Fill and bleed brake system. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications REAR WHEEL ANTILOCK (RWAL) BRAKES: Mounting Screws ................................................................................................................................. ................................................ 6 Nm (53 inch lbs.) FOUR WHEEL ANTILOCK BRAKES: CAB Screws ........................................................................................................................................ ................................ 4 - 4.7 Nm (36 - 42 inch lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > EBC 2 Antilock Brake Controller (EBC) 2 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > EBC 2 > Page 4302 Antilock Brake Controller (EBC) 325 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Connector Plug C1 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Connector Plug C1 > Page 4305 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Controller Antilock Brake (CAB) Electronic Brake Control Module: Description and Operation Controller Antilock Brake (CAB) The controller antilock brake module is used to monitor wheel speeds and modulates (control) hydraulic pressure in each brake channel. The modulated hydraulic pressure is used to prevent wheel lock up during braking. The CAB also provides a vehicle speed signal (VSS) to the powertrain control module. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Controller Antilock Brake (CAB) > Page 4308 Electronic Brake Control Module: Description and Operation With Four Wheel Antilock Brakes 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. The CAB contains dual microprocessors. A logic block in each microprocessor receives identical sensor signals. These signals are processed and compared simultaneously. 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. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Controller Antilock Brake (CAB) > Page 4309 Electronic Brake Control Module: Description and Operation With Rear Wheel Antilock Brakes 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. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. 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 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. 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 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System Electronic Brake Control Module: Service and Repair Four Wheel Antilock Brake System NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. REMOVAL 1. Disconnect battery negative cable. Harness Connector Locks 2. Push the harness connector locks to release the locks, then remove the connectors from the CAB. Pump Motor Connector 3. Disconnect the pump motor connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 4312 Controller Mounting Screws 4. Remove screws attaching CAB to the HCU. 5. Remove the CAB. INSTALLATION 1. Place the CAB onto the HCU. NOTE: Insure the CAB seal is in position before installation. 2. Install the mounting screws and tighten to 4 - 4.7 Nm (36 - 42 inch lbs.). 3. Connect the pump motor harness. 4. Connect the harnesses to the CAB and lock the connectors. 5. Connect battery. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 4313 Electronic Brake Control Module: Service and Repair Rear Wheel Antilock Brake System NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. REMOVAL RWAL Controller 1. Push the CAB harness connector lock to release the lock and remove the connector from the controller. 2. Remove the RWAL valve harness connector from the controller. 3. Remove the controller mounting screws and remove the controller from the mounting bracket. INSTALLATION 1. Position the controller on the bracket. 2. Install the mounting screws and tighten to 6 Nm (53 inch 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations Brake Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 4318 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 4319 Brake Fluid Pressure Sensor/Switch: Testing and Inspection PRESSURE DIFFERENTIAL SWITCH 1. Have 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations Brake Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 4323 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Rear Wheel Anti-Lock (RWAL) Brakes Mounting Bolt 200 in.lb Front Wheel Anti-Lock Brakes Front Sensor Bolt 190 in.lb Rear Sensor Bolt 200 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Rear Wheel Speed Sensor Tone Wheel Front Wheel Speed Sensor Rear Wheel Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4329 Wheel Speed Sensor: Connector Locations Left Front Wheel Speed Sensor Connector Right Front Wheel Speed Sensor Connector Rear Wheel Speed Sensor Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front Wheel Speed Sensor: Diagrams Front Connector Pin Identification Connector Pin Identification Connector Pin Identification Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front > Page 4332 Connector Pin Identification Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes Wheel Speed Sensor: Description and Operation Four Wheel Antilock Brakes The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front steering knuckles. The third sensor is mounted on top of the rear axle differential housing. The sensor is a magnet coil that is mounted over a tone wheel front/exciter ring rear with an air gap between them. The sensors measure the wheel speed by monitoring the rotation of the tone wheels front/exciter ring rear. As the teeth of the tone wheels front/exciter ring rear move through the magnetic field of the sensor an AC voltage is generated. This signal frequency increases or decreases proportionally to the speed of the wheel. The CAB monitors these signals for changes in wheel deceleration. If the CAB detects a sudden wheel or wheels deceleration within a predetermined amount the CAB will activate the ABS system. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 4335 Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brakes Rear Wheel Speed Sensor Location The rear Wheel Speed Sensor (WSS) is mounted in the rear differential housing. 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. Exciter Ring Location The exciter ring is press fitted onto the differential carrier next to the final drive ring gear. Operation Of The Wheel Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 4336 When the ring gear is rotated, the exciter ring passes the tip of the WSS. As the exciter ring passes the tip of the WSS, the magnetic lines of force of the sensor are cut, causing the magnetic field to be moved across the sensor's windings. This, in turn causes current to flow through the WSS circuit. 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 rotates, the stronger the signal will be - Distance between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring, 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. Data Link Connector - Typical The assembly plant performs a "Rolls Test" on every vehicle that leaves the assembly plant. One of the tests 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Front CAUTION: Special bolts are used to attach the front sensor. The bolts have a special shoulder, thread length and surface treatment. If the original bolts must be replaced, use only factory replacement bolts. Do not use substitute bolt under any circumstances. REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper and rotor. Front Wheel Speed Sensor - 4X4 4. Remove bolts attaching sensor to hub/bearing. 5. Remove clamps securing sensor wire to control arm and inner fender panel. 6. In engine compartment, disconnect sensor wire and remove sensor. INSTALLATION 1. Guide sensor wire around upper control arm. 2. Position sensor on hub/bearing and install attaching bolts. Tighten bolt to 18 - 25 Nm (160 - 220 inch lbs.). 3. Secure sensor wire retaining clamps to control arm and fender panel with original hardware. 4. In engine compartment, connect sensor wire to harness connector. Insure wire is routed away from hot or rotating underhood components. 5. Install brake rotor and caliper. 6. Install wheel and tire assembly. 7. Turn steering wheel back and forth that wire is clear of steering and suspension components. 8. Remove supports and lower vehicle. With Rear Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4339 Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 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. With Four Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4340 Wheel Speed Sensor: Service and Repair Tone Wheel Replacement Front Tone Wheel Tone Wheel 4X2 The tone wheel for the front speed sensor is located on the hub/bearing on 2-wheel drive models. On 4-wheel drive models, the tone wheel is located in the hub/bearing housing. The tone wheel is not a serviceable component. To replace the tone wheel the hub/bearing must be replaced. Rear Tone Wheel The toothed exciter ring is press-fitted onto the differential carrier next to the final drive ring gear in the differential case. If the ring is damaged, refer to Transmission and Drivetrain for service procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Battery Temperature Sensor The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4346 Battery Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4347 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4348 Battery Temperature Sensor: Description and Operation DESCRIPTION The battery temperature sensor is attached to the battery tray located under the battery. OPERATION The battery temperature sensor 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. BATTERY TEMPERATURE SENSOR-PCM INPUT Provides a signal to the PCM corresponding to the battery temperature. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor 1. The sensor is located on the front of the battery tray. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25° C (75-80° F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 4351 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. REMOVAL 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Removal/Installation. On vehicles equipped with an automatic transmission and a steering column mounted shifter an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced.. On vehicles equipped with an automatic transmission and a floor mounted shifter , a cable connects the interlock device within the steering column assembly, to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. The shifter interlock cable can be adjusted or replaced. SYSTEM DESCRIPTION The key-in ignition switch is integral to the ignition switch, which is mounted on the right side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition lock cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition lock cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4356 Ignition Switch Lock Cylinder: Service and Repair The ignition key must be in the key cylinder for cylinder removal. REMOVAL 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. Shroud Removal/Installation - Typical 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Retaining Pin 5. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4357 Flag In RUN Position Key Cylinder-Rear View Switch Mounting Screws 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4358 Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed. 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Ignition Switch View From Column Park Lock Linkage-Automatic Transmission-Typical Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4359 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkage before installing switch. Steering Wheel Lock Lever 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 3 Nm ± 0.5 Nm (26 in. lbs. ± 4 in. lbs.) torque. 11. Connect electrical connectors to ignition switch and halo lamp. Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). Tighten screws to 2 Nm (17 in. lbs.) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery. 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY; LOCK, OFF, ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify. Steering wheel should unlock when key is rotated to ON position. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Switch, park/neutral 25 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 4363 Output Shaft Speed Sensor, Park/Neutral Switch, Transmission Solenoid 8-Way Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 4364 Park/Neutral Position Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 4365 Neutral Safety Switch: Service and Repair REMOVAL 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. INSTALLATION Fig. 19 1. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 2. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 3. Test continuity of new switch with 12V test lamp. 4. Connect switch wires and lower vehicle. 5. Top off transmission fluid level. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Center The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4370 Starter Relay: Diagrams Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4371 Engine Starter Motor Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4372 Starter Relay: Description and Operation STARTER RELAY DESCRIPTION The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when the ignition switch is turned to the Start position. The starter 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 starter relay identification and location. The starter 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 starter relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. OPERATION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4373 Starter Relay: Testing and Inspection Starter Relay The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the fuse and relay layout label affixed to the underside of the PDC cover for starter relay identification and location. 1. Remove the starter relay from the PDC. Refer to Starter Relay/Service and Repair 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 starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay It is energized when the ignition switch is held in the Start position. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position, and no voltage when the ignition switch is released to the On position. If OK, go to Step 5. If not OK, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder Diagnosis. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded through the park/neutral position switch only when the gearshift selector lever is in the Park or Neutral positions. Check for continuity to ground at the cavity for relay terminal 85. If not OK, check for an open or short circuit to the park/neutral position switch and repair, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4374 Starter Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Distribution Center 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 starter relay identification and location. 4. Remove the starter relay from the PDC. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper starter relay location. 2. Position the starter relay in the proper receptacle in the PDC. 3. Align the starter relay terminals with the terminal cavities in the PDC receptacle. 4. Push down firmly on the starter relay until the terminals are fully seated in the terminal cavities in the PDC receptacle. 5. Install the cover onto the PDC. 6. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Battery Temperature Sensor The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4379 Battery Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4380 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4381 Battery Temperature Sensor: Description and Operation DESCRIPTION The battery temperature sensor is attached to the battery tray located under the battery. OPERATION The battery temperature sensor 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. BATTERY TEMPERATURE SENSOR-PCM INPUT Provides a signal to the PCM corresponding to the battery temperature. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor 1. The sensor is located on the front of the battery tray. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25° C (75-80° F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 4384 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. REMOVAL 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Lamp/Indicator > Component Information > Description and Operation Alternator Lamp/Indicator: Description and Operation GENERATOR LAMP-PCM OUTPUT If the Powertrain Control Module (PCM) senses a low charging condition in the charging system, it will illuminate the generator lamp (if equipped) on the instrument panel. This is done through the CCD Bus circuits. For example, during low idle with all accessories turned on, the lamp may momentarily go on. Once the PCM corrects idle speed to a higher rpm, the lamp will go out. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Locations Voltage Regulator: Locations Electronic Voltage Regulator is a voltage regulating circuit located within the Powertrain Control Module (PCM). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Locations > Page 4393 Voltage Regulator: Description and Operation DESCRIPTION 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. OPERATION 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 and battery temperature (refer to Battery Temperature Sensor for more information). It then compensates and regulates generator current output accordingly. Also refer to Charging System Operation for additional information. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Removal/Installation. On vehicles equipped with an automatic transmission and a steering column mounted shifter an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced.. On vehicles equipped with an automatic transmission and a floor mounted shifter , a cable connects the interlock device within the steering column assembly, to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. The shifter interlock cable can be adjusted or replaced. SYSTEM DESCRIPTION The key-in ignition switch is integral to the ignition switch, which is mounted on the right side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition lock cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition lock cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4399 Ignition Switch Lock Cylinder: Service and Repair The ignition key must be in the key cylinder for cylinder removal. REMOVAL 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. Shroud Removal/Installation - Typical 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Retaining Pin 5. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4400 Flag In RUN Position Key Cylinder-Rear View Switch Mounting Screws 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4401 Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed. 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Ignition Switch View From Column Park Lock Linkage-Automatic Transmission-Typical Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4402 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkage before installing switch. Steering Wheel Lock Lever 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 3 Nm ± 0.5 Nm (26 in. lbs. ± 4 in. lbs.) torque. 11. Connect electrical connectors to ignition switch and halo lamp. Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). Tighten screws to 2 Nm (17 in. lbs.) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery. 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY; LOCK, OFF, ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify. Steering wheel should unlock when key is rotated to ON position. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Switch, park/neutral 25 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Specifications > Page 4406 Output Shaft Speed Sensor, Park/Neutral Switch, Transmission Solenoid 8-Way Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Specifications > Page 4407 Park/Neutral Position Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Specifications > Page 4408 Neutral Safety Switch: Service and Repair REMOVAL 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. INSTALLATION Fig. 19 1. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 2. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 3. Test continuity of new switch with 12V test lamp. 4. Connect switch wires and lower vehicle. 5. Top off transmission fluid level. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications Starter Motor: Electrical Specifications Power Rating 1.9 hp Voltage 12 V Free-Running Test Voltage 11 V Free-Running Test Amperage Draw 73 A Free-Running Test Minimum Speed 3601 rpm Solenoid Closing Maximum Voltage Required 7.5 V Cranking Amperage Draw Test 125 - 150 A Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications > Page 4413 Starter Motor: Mechanical Specifications Upper/Lower Starter Mounting Screw 50 ft.lb Battery (+) Cable to Solenoid Battery Terminal Nut 120 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4414 Starter Motor: Locations Starter Motor Remove/Install The starter motor is located on the left side of the engine. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4415 Starter Motor: Application and ID Manufacturer = Nippon Denso Part Number = 56027702AB Pinion Teeth = 10 No. of Brushes = 4 No. of Fields = 4 No. of Poles = 4 Drive = Reduction Gear Train Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4416 Starter Motor: Description and Operation STARTER MOTOR DESCRIPTION The starter motors used for all engines available in this model are interchangeable. The starter motors are all mounted with one screw, a stud and a nut to the automatic transmission torque converter housing and are located on the left side of the engine. This starter motor incorporates several features to create a reliable, efficient, compact, lightweight and powerful unit. The electric motors of these starters feature four electromagnetic field coils wound around four pole shoes, and four brushes contact the motor commutator. These starter motors are all rated at 1.4 kilowatts (about 1.9 horsepower) output at 12 volts. These starter motors are serviced only as a unit with their starter solenoids, and cannot be repaired. If either component is faulty or damaged, the entire starter motor and starter solenoid unit must be replaced. OPERATION This 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 pillion 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. These starter motors are 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, also engaging and disengaging the starter pinion gear with the starter ring gear. This starter motor uses an overrunning clutch and starter pinion gear unit to engage and drive a starter ring gear that is integral to the torque converter or torque converter drive plate mounted on the rear crankshaft flange. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4417 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 the starter motor removed from the vehicle. Refer to the starter motor specifications. 1. Remove the starter motor from the vehicle. 2. Mount the starter motor securely in a soft-jawed bench vise. The vise jaws should be clamped on the mounting flange of the starter motor. Never clamp on the starter motor by the field frame. 3. Connect a suitable volt-ampere tester and a 12-volt battery to the starter motor in series, and set the ammeter to the 100 ampere scale. See the instructions provided by the manufacturer of the volt-ampere tester being used. 4. Install a jumper wire from the solenoid terminal to the solenoid battery terminal. The starter motor should operate. If the starter motor fails to operate, replace the faulty starter motor assembly. 5. Adjust the carbon pile load of the tester to obtain the free running test voltage. Refer to the starter motor free running test voltage specifications. 6. Note the reading on the ammeter and compare this reading to the free running test maximum amperage draw. Refer to the starter motor free running test maximum amperage draw specifications. 7. If the ammeter reading exceeds the maximum amperage draw specification, replace the faulty starter motor assembly. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4418 Starter Motor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Raise and support the vehicle. Starter Motor Remove/Install 3. Remove the nut and lock washer securing the starter motor to the mounting stud on the transmission torque converter housing. 4. While supporting the starter motor with one hand, use the other hand to remove the upper mounting screw from the starter motor. 5. Slide the automatic transmission cooler tube bracket forward on the tubes and off of the mounting stud far enough for the starter motor mounting flange to be removed from the stud. 6. Move the starter motor towards the front of the vehicle far enough for the nose of the starter pinion housing to clear the transmission torque converter housing. Always support the starter motor during this process, do not let the starter motor hang from the wire harness. 7. Tilt the nose downwards and lower the starter motor far enough to access and remove the nut that secures the battery positive cable connector eyelet to the solenoid battery terminal stud. Always support the starter motor during this process, do not let the starter motor hang from the wire harness. 8. Remove the battery positive cable connector eyelet from the solenoid battery terminal stud. Always support the starter motor during this process, do not let the starter motor hang from the wire harness. 9. Disconnect the battery positive cable wire harness connector from the solenoid terminal connector receptacle. Always support the starter motor during this process, do not let the starter motor hang from the wire harness. 10. Remove the starter motor from the engine compartment. INSTALLATION 1. Position the starter motor in the engine compartment. 2. Reconnect the battery positive cable wire harness connector to the solenoid terminal connector receptacle. Always support the starter motor during this process, do not let the starter motor hang from the wire harness. 3. Install the battery positive cable connector eyelet over the solenoid battery terminal stud. Always support the starter motor during this process, do not let the starter motor hang from the wire harness. 4. Install and tighten the nut that secures the battery positive cable connector eyelet to the solenoid battery terminal stud. Tighten the nut to 13.6 Nm (120 in. lbs.). Always support the starter motor during this process, do not let the starter motor hang from the wire harness. 5. Position the starter motor to the front of the transmission torque converter housing. 6. Slide the automatic transmission cooler tube bracket rearward on the tubes and onto the lower starter motor mounting stud. 7. Loosely install the screw that secures the upper starter motor mounting flange to the transmission torque converter housing. 8. Install the lock washer and loosely install the nut securing the starter motor to the lower mounting stud on the transmission torque converter housing. 9. Tighten the upper starter motor mounting screw. Tighten the screw to 67.8 Nm (50 ft. lbs.). 10. Tighten the lower starter motor mounting nut. Tighten the nut to 67.8 Nm (50 ft. lbs.). 11. Lower the vehicle. 12. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Center The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4422 Starter Relay: Diagrams Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4423 Engine Starter Motor Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4424 Starter Relay: Description and Operation STARTER RELAY DESCRIPTION The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when the ignition switch is turned to the Start position. The starter 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 starter relay identification and location. The starter 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 starter relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. OPERATION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4425 Starter Relay: Testing and Inspection Starter Relay The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the fuse and relay layout label affixed to the underside of the PDC cover for starter relay identification and location. 1. Remove the starter relay from the PDC. Refer to Starter Relay/Service and Repair 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 starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay It is energized when the ignition switch is held in the Start position. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position, and no voltage when the ignition switch is released to the On position. If OK, go to Step 5. If not OK, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder Diagnosis. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded through the park/neutral position switch only when the gearshift selector lever is in the Park or Neutral positions. Check for continuity to ground at the cavity for relay terminal 85. If not OK, check for an open or short circuit to the park/neutral position switch and repair, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4426 Starter Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Distribution Center 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 starter relay identification and location. 4. Remove the starter relay from the PDC. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper starter relay location. 2. Position the starter relay in the proper receptacle in the PDC. 3. Align the starter relay terminals with the terminal cavities in the PDC receptacle. 4. Push down firmly on the starter relay until the terminals are fully seated in the terminal cavities in the PDC receptacle. 5. Install the cover onto the PDC. 6. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications Starter Solenoid: Specifications Solenoid Closing Maximum Voltage Required 7.5 V Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 4430 Starter Solenoid: Application and ID Manufacturer = Nippon Denso Part Number = 56027702AB Pinion Teeth = 10 No. of Brushes = 4 No. of Fields = 4 No. of Poles = 4 Drive = Reduction Gear Train Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 4431 Starter Solenoid: Testing and Inspection This test can only be performed with the starter motor removed from the vehicle. 1. Remove the starter motor from the vehicle. Refer to Starter Motor/Service and Repair for the procedures. 2. Disconnect the wire from the solenoid field coil terminal. Continuity Test Between Solenoid Terminal And Field Coil Terminal - Typical 3. Check for continuity between the solenoid terminal and the solenoid field coil terminal with a continuity tester. There should be continuity. If OK, go to Step 4. If not OK, replace the faulty starter motor assembly. Continuity Test Between Solenoid Terminal And Solenoid Case - Typical 4. Check for continuity between the solenoid terminal and the solenoid case. There should be continuity. If not OK, replace the faulty starter motor assembly. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations Auxiliary Power Outlet: Locations Instrument Panel Cigar Lighter And Power Outlet The power outlet is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4438 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4439 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4440 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4441 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4442 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4443 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4444 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4445 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4446 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4447 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4448 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4449 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4450 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4451 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4452 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4453 Auxiliary Power Outlet: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4454 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4455 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4456 Auxiliary Power Outlet: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4457 Auxiliary Power Outlet: Description and Operation INSTRUMENT PANEL POWER OUTLET DESCRIPTION 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. OPERATION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4458 Auxiliary Power Outlet: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4459 Auxiliary Power Outlet: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the lower bezel from the instrument panel. Refer to Instrument Panel Lower Bezel/Service and Repair for the procedures. Instrument Panel Cigar Lighter And Power Outlet 3. Pull the cigar lighter knob and element out of the cigar lighter receptacle base, or unsnap the protective cap from the power outlet receptacle base. Cigar Lighter And Power Outlet Remove/Install - Typical 4. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses of the mount that secures the receptacle base to the instrument panel lower bezel. 5. Insert a pair of external snap ring pliers into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 6. 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. 7. Remove the cigar lighter or power outlet mount from the instrument panel lower bezel. INSTALLATION 1. Install the cigar lighter or power outlet mount into the instrument panel lower bezel. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4460 4. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 5. Install the lower bezel onto the instrument panel. Refer to Instrument Panel Lower Bezel/Service and Repair for the procedures. 6. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications Power Distribution Center: Specifications Tighten the screw that secures the PDC to the left front fender wheel housing to 7.9 Nm (70 in. lbs.). Tighten the nut that secures the eyelet of the battery positive cable take out to the forward stud in the PDC to 8.4 Nm (75 in. lbs.). Tighten the nut that secures the eyelet of the battery negative cable take out to the rearward stud in the PDC to 9 Nm (80 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications > Page 4464 Power Distribution Center: Locations Power Distribution Center (PDC) Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications > Page 4465 Power Distribution Center: Diagrams Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications > Page 4466 Fuses And A/C Compressor Clutch Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications > Page 4467 Automatic Shutdown, Blower Motor, & Starter Motor Relays Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications > Page 4468 Fog Lamp, Fuel Pump And Headlamp Relays Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications > Page 4469 Horn, Ignition (Max Cooling) & Trailer Tow Relays Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications > Page 4470 Transmission Control & Wiper Relays And C106 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications > Page 4471 Power Distribution Center: Description and Operation Power Distribution Center Power Distribution Center All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC). The molded plastic PDC housing is located in the left front corner of the engine compartment, just behind the battery. The PDC housing has a molded plastic cover that includes two integral latches, one on each side. The PDC cover is easily 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 housing is secured in the engine compartment at three points. Integral mounts on the front and inboard end 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 cover is unlatched and removed to access the battery/ generator cable input and output connection studs. The PDC is integral to the headlamp and dash wire harness, which exits from the outboard end of the PDC housing. All of the current from the battery/generator cable connections enters the PDC through a 140 ampere generator cartridge fuse that is secured with screws just inside the inboard end of the PDC housing. The PDC houses 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. Internal connection of all of the PDC circuits is accomplished by an intricate combination of hard wiring and bus bars. The cartridge fuses, blade-type fuses and relays are available for service replacement. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications > Page 4472 Power Distribution Center: Service and Repair 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 if the PDC housing is faulty or damaged, the entire PDC and the headlamp and dash wire harness unit must be replaced. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Disconnect each of the headlamp and dash wire harness connectors. 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. 4. Disengage each of the retainers that secure the headlamp and dash wire harness to the vehicle body and chassis components. 5. Unlatch and remove the cover from the PDC. Engine Wire Harness In-Line Connector 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. Battery Cable To PDC Connections 8. Remove the nut that secures the eyelet of the battery negative cable take out to the rearward stud in the PDC and remove the eyelet from the stud. 9. Remove the nut that secures the eyelet of the battery positive cable take out to the forward stud in the PDC and remove the eyelet from the stud. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications > Page 4473 Power Distribution Center Remove/Install 10. Remove the screw that secures the PDC 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 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 old PDC to the proper cavities of the new PDC. 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 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 take out onto the forward stud in the PDC. 5. Install and tighten the nut that secures the eyelet of the battery positive cable take out to the forward stud in the PDC. Tighten the nut to 8.4 Nm (75 in. lbs.). 6. Install the eyelet of the battery negative cable take out onto the rearward stud in the PDC. 7. Install and tighten the nut that secures the eyelet of the battery negative cable take out to the rearward 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 connector receptacle. 10. Install 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. 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. 13. Reconnect each of the headlamp and dash wire harness connectors. 14. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Specifications Electronic Noise Suppressor: Specifications Tighten the nut that secures the right engine-to-body ground strap eyelet to the rear valve cover stud of the right cylinder head to 5.0 Nm (45 in. lbs.). Tighten the screw that secures the right engine-to-body ground strap eyelet to the lower rear corner of the right cylinder head. Tighten the screw to 10.7 Nm (95 in. lbs.). Tighten the screw that secures the left engine-to-body ground strap eyelet to the lower rear corner of the left cylinder head. Tighten the screw to 10.7 Nm (95 in. lbs.). Tighten the nut that secures the right engine-to-body ground strap eyelet to the inboard speed control servo mounting stud on the right side of the lower plenum panel. Tighten the nut to 3.9 Nm (35 in. lbs.). Tighten the nut that secures the left engine-to-body ground strap eyelet to the stud on the left side of the lower plenum panel. Tighten the nut to 3.9 Nm (35 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Specifications > Page 4477 Electronic Noise Suppressor: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Specifications > Page 4478 Electronic Noise Suppressor: Description and Operation RADIO NOISE SUPPRESSION DESCRIPTION Radio Frequency Interference (RFI) and Electro Magnetic 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) - Resistor-type spark plugs - Radio suppression-type secondary ignition wiring. For more information on the spark plugs and secondary ignition components, refer to Ignition System Description and Operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Specifications > Page 4479 Electronic Noise Suppressor: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL Engine-to-body Ground Straps Engine-To-Body Ground Strap Remove/Install 1. Remove the nut that secures the left engine-to- body ground strap eyelet to the stud on the left side of the lower plenum panel. 2. Remove the nut that secures the right engine-to-body ground strap eyelet to the inboard speed control servo mounting stud on the right side of the lower plenum panel. Engine-To-Body Ground Strap Remove/Install 3. Remove the screw that secures the left engine-to-body ground strap eyelet to the lower rear corner of the left cylinder head. 4. Remove the screw that secures the right engine-to-body ground strap eyelet to the lower rear corner of the right cylinder head. 5. Remove the nut that secures the right engine-to-body ground strap eyelet to the rear valve cover stud of the right cylinder head. 6. Remove the engine-to-body ground strap from the engine compartment. INSTALLATION Engine-to-body Ground Straps 1. Position the engine-to-body ground strap in the engine compartment. 2. Position the right engine-to-body ground strap eyelet over the rear valve cover stud of the right cylinder head. 3. Install and tighten the nut that secures the right engine-to-body ground strap eyelet to the rear valve cover stud of the right cylinder head. Tighten the nut to 5.0 Nm (45 in. lbs.). 4. Install and tighten the screw that secures the right engine-to-body ground strap eyelet to the lower rear corner of the right cylinder head. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Specifications > Page 4480 Tighten the screw to 10.7 Nm (95 in. lbs.). 5. Install and tighten the screw that secures the left engine-to-body ground strap eyelet to the lower rear corner of the left cylinder head. Tighten the screw to 10.7 Nm (95 in. lbs.). 6. Position the right engine-to-body ground strap eyelet over the inboard speed control servo mounting stud on the right side of the lower plenum panel. 7. Install and tighten the nut that secures the right engine-to-body ground strap eyelet to the inboard speed control servo mounting stud on the right side of the lower plenum panel. Tighten the nut to 3.9 Nm (35 in. lbs.). 8. Position the left engine-to-body ground strap eyelet over the stud on the left side of the lower plenum panel. 9. Install and tighten the nut that secures the left engine-to-body ground strap eyelet to the stud on the left side of the lower plenum panel. Tighten the nut to 3.9 Nm (35 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > DTC's - Caused By Open Fuses Fuse: Technical Service Bulletins DTC's - Caused By Open Fuses NUMBER: 18-09-99 GROUP: Vehicle Performance DATE: May 21, 1999 SUBJECT: Common Diagnostic Trouble Codes Caused By An Open Fuse. MODELS: 1999 (AB) Ram Van 1999 (AN) Dakota 1999 (BR/BE) Ram Truck 1999 (DN) Durango 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1999 (XJ) Cherokee DISCUSSION: Recent quality analysis has revealed an issue with repeated repairs for the same Diagnostic Trouble Code (DTC). The DTC may be due to an overlooked open circuit used to power the component in question. In most instances, either the circuit fuse has been erroneously removed or the fuse itself has an open (blown). The component in question, and its circuit, are often protected by two fuses. It is usually the lower amperage fuse that is either missing or open. The lower amperage fuse is positioned electrically in the circuit between the component in question and either a relay (Auto Shut Down, 02 heater) or the ignition switch. The lower amperage fuse will be located either in the underhood Power Distribution Center (PDC) or in the instrument panel Junction Block. The lower amperage fuse is often missing because it was removed erroneously for use in another low current circuit. If the lower amperage fuse is open (blown), then the circuit and component in question must be checked for an electrical short. Check to make sure that the open fuse was not exchanged with another fuse or was damaged by an installed accessory. NOTE: IF AN OXYGEN SENSOR IS REPLACED, VERIFY THAT THE CIRCUIT FUSE IS GOOD. AN OXYGEN SENSOR HEATER, WHEN DAMAGED OR OVERHEATED, MAY SHORT THE CIRCUIT AND CAUSE THE FUSE TO OPEN (BLOW). The higher amperage fuse should be checked, but is not normally the cause of the DTC. The higher amperage fuse is located in the underhood PDC. It is positioned electrically in the circuit between the battery and either the relay (Auto Shut Down, 02 heater) or the ignition switch. Refer to the applicable Diagnostic Procedures Manual and/or Service Manual (Group 8) for further technical assistance. The following is a list of the components frequently replaced erroneously due to an open fuse. Included are the possible DTC(s) which would be generated as a result. 1). Oxygen Sensor (02) P0132 ($3E) = 1/1 02 Sensor Shorted to Voltage P0135 ($67) = 1/1 02 Sensor Heater Failure P0138 ($7E) = 1/2 02 Sensor Shorted to Voltage P0141 ($69) = 1/2 02 Sensor Heater Failure P0152 ($42) = 2/1 02 Sensor Shorted To Voltage P0155 ($7C) = 2/1 02 Sensor Heater Failure P0158 ($7F) = 2/2 02 Sensor Shorted To Voltage P0161 ($7D) = 2/2 02 Sensor Heater Failure 2). Leak Detection Pump (LDP) P1495 ($B7) = Leak Detection Pump Solenoid Circuit Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > DTC's - Caused By Open Fuses > Page 4485 3). Evaporative Purge Solenoid (DCP) P0443 ($12) = Evaporative Purge Solenoid Circuit 4). Torque Converter Clutch Solenoid (TCC) P0743 ($OC) = Torque Converter Clutch Solenoid / Trans Relay Circuits POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4488 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4489 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4490 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4491 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4492 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4493 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4494 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4495 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4496 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4497 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4498 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4499 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4500 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4501 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4502 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4503 Fuse: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4504 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4505 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4506 Fuse: Connector Views Relay And Fuse Box Fuses Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4507 Fuse: Electrical Diagrams 8w-11-003 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4508 8w-11-004 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4509 8w-11-005 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Specifications Fuse Block: Specifications Tighten the one screw that secures the junction block to the left instrument panel end bracket to 2.2 Nm (20 in. lbs.). Tighten the one screw that secures the junction block to the left instrument panel end bracket to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Specifications > Page 4513 Fuse Block: Locations Junction (Fuse) Block Junction Block Relay And Fuse Block Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4516 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4517 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4518 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4519 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4520 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4521 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4522 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4523 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4524 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4525 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4526 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4527 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4528 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4529 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4530 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4531 Fuse Block: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4532 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4533 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4534 Fuse Block: Connector Views 8w-12-2 Junction Block (Front View) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4535 8w-12-3 Junction Block (Rear View) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4536 8w-12-4 Fuses Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4537 8w-11-002 Fuse Block Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4538 Fuse Block: Electrical Diagrams Fuse Block 8w-11-003 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4539 8w-11-004 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4540 8w-11-005 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Junction Block Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4541 8w-12-5 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4542 8w-12-6 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4543 8w-12-7 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4544 8w-12-8 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4545 8w-12-9 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4546 8w-12-10 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4547 8w-12-11 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4548 8w-12-12 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4549 8w-12-13 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4550 8w-12-14 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4551 8w-12-15 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4552 8w-12-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4553 Fuse Block: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO 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 AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4554 Fuse Block: Description and Operation DESCRIPTION Junction Block Junction Block An electrical Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. 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 junction block fuses. 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 label to ensure proper fuse identification. The JB combines the functions previously provided by a separate fuseblock module and relay center, 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. 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. 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). Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. The fuses, circuit breakers, and relays are available for service replacement. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or if the JB housing is faulty or damaged, the entire JB unit must be replaced. Relay And Fuse Block An additional relay and fuse block is used on this model. 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. 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 Junction Block (JB) or the Power Distribution Center (PDC). Relay And Fuse Block Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4555 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 is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. The relay and fuse block has cavities for up to four additional blade-type mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. The fuses, flasher and relays are available for service replacement. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Junction Block Replacement Fuse Block: Service and Repair Junction Block Replacement WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO 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 AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. Fuse Access Panel Remove/Install 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. Reaching through the instrument panel fuse access panel opening, remove the one screw that secures the junction block to the left instrument panel end bracket. 4. Remove the steering column opening cover from the instrument panel. Refer to Steering Column Opening Cover/Service and Repair of Instrument Panel Systems for the procedures. 5. Reach through the outboard side of the instrument panel steering column opening to access the junction block. Junction Block Remove/Install 6. Disconnect all of the wire harness connectors from the connector receptacles on the back of the junction block. 7. Still reaching through the instrument panel steering column opening, remove the relay and fuse block from the junction block. 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. 8. Still reaching through the outboard side of the instrument panel steering column opening, remove the one screw that secures the junction block to the left instrument panel end bracket. 9. Remove the junction block from the left instrument panel end bracket. INSTALLATION 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 old JB to the proper cavities of the new JB. 1. Position the junction block onto the left instrument panel end bracket. 2. 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.). 3. Install the relay and fuse block onto the junction block by engaging its mounting slots with the tabs on the junction block. 4. Reconnect all of the wire harness connectors to the connector receptacles on the back of the junction block. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Junction Block Replacement > Page 4558 5. Install the steering column opening cover onto the instrument panel. Refer to Steering Column Opening Cover/Service and Repair of Instrument Panel Systems for the procedures. 6. Reaching through the instrument panel fuse access panel opening, 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Junction Block Replacement > Page 4559 Fuse Block: Service and Repair Relay and Fuse Block Replacement 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 if 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 AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the dash panel. Refer to Instrument Panel Assembly in Instrument Panel Systems for the procedures. 3. Disconnect each of the instrument panel wire harness connectors. 4. Remove all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. 5. Disengage each of the retainers that secure the instrument panel wire harness to the instrument panel components. 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. 7. Remove the relay and fuse block and the instrument panel wire harness from the instrument panel as a unit. INSTALLATION 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 old relay and fuse block to the proper cavities of the new relay and fuse block. 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. 3. Engage each of the retainers that secure the instrument panel wire harness to the instrument panel components. 4. Install all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. 5. Reconnect each of the instrument panel wire harness connectors. 6. Install the instrument panel assembly onto the dash panel. 7. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations Auxiliary Power Outlet: Locations Instrument Panel Cigar Lighter And Power Outlet The power outlet is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4573 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4574 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4575 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4576 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4577 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4578 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4579 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4580 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4581 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4582 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4583 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4584 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4585 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4586 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4587 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4588 Auxiliary Power Outlet: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4589 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4590 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4591 Auxiliary Power Outlet: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4592 Auxiliary Power Outlet: Description and Operation INSTRUMENT PANEL POWER OUTLET DESCRIPTION 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. OPERATION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4593 Auxiliary Power Outlet: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4594 Auxiliary Power Outlet: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the lower bezel from the instrument panel. Refer to Instrument Panel Lower Bezel/Service and Repair for the procedures. Instrument Panel Cigar Lighter And Power Outlet 3. Pull the cigar lighter knob and element out of the cigar lighter receptacle base, or unsnap the protective cap from the power outlet receptacle base. Cigar Lighter And Power Outlet Remove/Install - Typical 4. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses of the mount that secures the receptacle base to the instrument panel lower bezel. 5. Insert a pair of external snap ring pliers into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 6. 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. 7. Remove the cigar lighter or power outlet mount from the instrument panel lower bezel. INSTALLATION 1. Install the cigar lighter or power outlet mount into the instrument panel lower bezel. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4595 4. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 5. Install the lower bezel onto the instrument panel. Refer to Instrument Panel Lower Bezel/Service and Repair for the procedures. 6. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications Power Distribution Center: Specifications Tighten the screw that secures the PDC to the left front fender wheel housing to 7.9 Nm (70 in. lbs.). Tighten the nut that secures the eyelet of the battery positive cable take out to the forward stud in the PDC to 8.4 Nm (75 in. lbs.). Tighten the nut that secures the eyelet of the battery negative cable take out to the rearward stud in the PDC to 9 Nm (80 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications > Page 4599 Power Distribution Center: Locations Power Distribution Center (PDC) Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications > Page 4600 Power Distribution Center: Diagrams Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications > Page 4601 Fuses And A/C Compressor Clutch Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications > Page 4602 Automatic Shutdown, Blower Motor, & Starter Motor Relays Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications > Page 4603 Fog Lamp, Fuel Pump And Headlamp Relays Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications > Page 4604 Horn, Ignition (Max Cooling) & Trailer Tow Relays Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications > Page 4605 Transmission Control & Wiper Relays And C106 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications > Page 4606 Power Distribution Center: Description and Operation Power Distribution Center Power Distribution Center All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC). The molded plastic PDC housing is located in the left front corner of the engine compartment, just behind the battery. The PDC housing has a molded plastic cover that includes two integral latches, one on each side. The PDC cover is easily 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 housing is secured in the engine compartment at three points. Integral mounts on the front and inboard end 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 cover is unlatched and removed to access the battery/ generator cable input and output connection studs. The PDC is integral to the headlamp and dash wire harness, which exits from the outboard end of the PDC housing. All of the current from the battery/generator cable connections enters the PDC through a 140 ampere generator cartridge fuse that is secured with screws just inside the inboard end of the PDC housing. The PDC houses 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. Internal connection of all of the PDC circuits is accomplished by an intricate combination of hard wiring and bus bars. The cartridge fuses, blade-type fuses and relays are available for service replacement. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications > Page 4607 Power Distribution Center: Service and Repair 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 if the PDC housing is faulty or damaged, the entire PDC and the headlamp and dash wire harness unit must be replaced. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Disconnect each of the headlamp and dash wire harness connectors. 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. 4. Disengage each of the retainers that secure the headlamp and dash wire harness to the vehicle body and chassis components. 5. Unlatch and remove the cover from the PDC. Engine Wire Harness In-Line Connector 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. Battery Cable To PDC Connections 8. Remove the nut that secures the eyelet of the battery negative cable take out to the rearward stud in the PDC and remove the eyelet from the stud. 9. Remove the nut that secures the eyelet of the battery positive cable take out to the forward stud in the PDC and remove the eyelet from the stud. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Specifications > Page 4608 Power Distribution Center Remove/Install 10. Remove the screw that secures the PDC 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 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 old PDC to the proper cavities of the new PDC. 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 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 take out onto the forward stud in the PDC. 5. Install and tighten the nut that secures the eyelet of the battery positive cable take out to the forward stud in the PDC. Tighten the nut to 8.4 Nm (75 in. lbs.). 6. Install the eyelet of the battery negative cable take out onto the rearward stud in the PDC. 7. Install and tighten the nut that secures the eyelet of the battery negative cable take out to the rearward 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 connector receptacle. 10. Install 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. 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. 13. Reconnect each of the headlamp and dash wire harness connectors. 14. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Specifications Electronic Noise Suppressor: Specifications Tighten the nut that secures the right engine-to-body ground strap eyelet to the rear valve cover stud of the right cylinder head to 5.0 Nm (45 in. lbs.). Tighten the screw that secures the right engine-to-body ground strap eyelet to the lower rear corner of the right cylinder head. Tighten the screw to 10.7 Nm (95 in. lbs.). Tighten the screw that secures the left engine-to-body ground strap eyelet to the lower rear corner of the left cylinder head. Tighten the screw to 10.7 Nm (95 in. lbs.). Tighten the nut that secures the right engine-to-body ground strap eyelet to the inboard speed control servo mounting stud on the right side of the lower plenum panel. Tighten the nut to 3.9 Nm (35 in. lbs.). Tighten the nut that secures the left engine-to-body ground strap eyelet to the stud on the left side of the lower plenum panel. Tighten the nut to 3.9 Nm (35 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Specifications > Page 4612 Electronic Noise Suppressor: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Specifications > Page 4613 Electronic Noise Suppressor: Description and Operation RADIO NOISE SUPPRESSION DESCRIPTION Radio Frequency Interference (RFI) and Electro Magnetic 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) - Resistor-type spark plugs - Radio suppression-type secondary ignition wiring. For more information on the spark plugs and secondary ignition components, refer to Ignition System Description and Operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Specifications > Page 4614 Electronic Noise Suppressor: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL Engine-to-body Ground Straps Engine-To-Body Ground Strap Remove/Install 1. Remove the nut that secures the left engine-to- body ground strap eyelet to the stud on the left side of the lower plenum panel. 2. Remove the nut that secures the right engine-to-body ground strap eyelet to the inboard speed control servo mounting stud on the right side of the lower plenum panel. Engine-To-Body Ground Strap Remove/Install 3. Remove the screw that secures the left engine-to-body ground strap eyelet to the lower rear corner of the left cylinder head. 4. Remove the screw that secures the right engine-to-body ground strap eyelet to the lower rear corner of the right cylinder head. 5. Remove the nut that secures the right engine-to-body ground strap eyelet to the rear valve cover stud of the right cylinder head. 6. Remove the engine-to-body ground strap from the engine compartment. INSTALLATION Engine-to-body Ground Straps 1. Position the engine-to-body ground strap in the engine compartment. 2. Position the right engine-to-body ground strap eyelet over the rear valve cover stud of the right cylinder head. 3. Install and tighten the nut that secures the right engine-to-body ground strap eyelet to the rear valve cover stud of the right cylinder head. Tighten the nut to 5.0 Nm (45 in. lbs.). 4. Install and tighten the screw that secures the right engine-to-body ground strap eyelet to the lower rear corner of the right cylinder head. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Specifications > Page 4615 Tighten the screw to 10.7 Nm (95 in. lbs.). 5. Install and tighten the screw that secures the left engine-to-body ground strap eyelet to the lower rear corner of the left cylinder head. Tighten the screw to 10.7 Nm (95 in. lbs.). 6. Position the right engine-to-body ground strap eyelet over the inboard speed control servo mounting stud on the right side of the lower plenum panel. 7. Install and tighten the nut that secures the right engine-to-body ground strap eyelet to the inboard speed control servo mounting stud on the right side of the lower plenum panel. Tighten the nut to 3.9 Nm (35 in. lbs.). 8. Position the left engine-to-body ground strap eyelet over the stud on the left side of the lower plenum panel. 9. Install and tighten the nut that secures the left engine-to-body ground strap eyelet to the stud on the left side of the lower plenum panel. Tighten the nut to 3.9 Nm (35 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > DTC's - Caused By Open Fuses Fuse: Technical Service Bulletins DTC's - Caused By Open Fuses NUMBER: 18-09-99 GROUP: Vehicle Performance DATE: May 21, 1999 SUBJECT: Common Diagnostic Trouble Codes Caused By An Open Fuse. MODELS: 1999 (AB) Ram Van 1999 (AN) Dakota 1999 (BR/BE) Ram Truck 1999 (DN) Durango 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1999 (XJ) Cherokee DISCUSSION: Recent quality analysis has revealed an issue with repeated repairs for the same Diagnostic Trouble Code (DTC). The DTC may be due to an overlooked open circuit used to power the component in question. In most instances, either the circuit fuse has been erroneously removed or the fuse itself has an open (blown). The component in question, and its circuit, are often protected by two fuses. It is usually the lower amperage fuse that is either missing or open. The lower amperage fuse is positioned electrically in the circuit between the component in question and either a relay (Auto Shut Down, 02 heater) or the ignition switch. The lower amperage fuse will be located either in the underhood Power Distribution Center (PDC) or in the instrument panel Junction Block. The lower amperage fuse is often missing because it was removed erroneously for use in another low current circuit. If the lower amperage fuse is open (blown), then the circuit and component in question must be checked for an electrical short. Check to make sure that the open fuse was not exchanged with another fuse or was damaged by an installed accessory. NOTE: IF AN OXYGEN SENSOR IS REPLACED, VERIFY THAT THE CIRCUIT FUSE IS GOOD. AN OXYGEN SENSOR HEATER, WHEN DAMAGED OR OVERHEATED, MAY SHORT THE CIRCUIT AND CAUSE THE FUSE TO OPEN (BLOW). The higher amperage fuse should be checked, but is not normally the cause of the DTC. The higher amperage fuse is located in the underhood PDC. It is positioned electrically in the circuit between the battery and either the relay (Auto Shut Down, 02 heater) or the ignition switch. Refer to the applicable Diagnostic Procedures Manual and/or Service Manual (Group 8) for further technical assistance. The following is a list of the components frequently replaced erroneously due to an open fuse. Included are the possible DTC(s) which would be generated as a result. 1). Oxygen Sensor (02) P0132 ($3E) = 1/1 02 Sensor Shorted to Voltage P0135 ($67) = 1/1 02 Sensor Heater Failure P0138 ($7E) = 1/2 02 Sensor Shorted to Voltage P0141 ($69) = 1/2 02 Sensor Heater Failure P0152 ($42) = 2/1 02 Sensor Shorted To Voltage P0155 ($7C) = 2/1 02 Sensor Heater Failure P0158 ($7F) = 2/2 02 Sensor Shorted To Voltage P0161 ($7D) = 2/2 02 Sensor Heater Failure 2). Leak Detection Pump (LDP) P1495 ($B7) = Leak Detection Pump Solenoid Circuit Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > DTC's - Caused By Open Fuses > Page 4620 3). Evaporative Purge Solenoid (DCP) P0443 ($12) = Evaporative Purge Solenoid Circuit 4). Torque Converter Clutch Solenoid (TCC) P0743 ($OC) = Torque Converter Clutch Solenoid / Trans Relay Circuits POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4623 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4624 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4625 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4626 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4627 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4628 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4629 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4630 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4631 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4632 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4633 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4634 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4635 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4636 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4637 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4638 Fuse: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4639 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4640 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4641 Fuse: Connector Views Relay And Fuse Box Fuses Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4642 Fuse: Electrical Diagrams 8w-11-003 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4643 8w-11-004 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4644 8w-11-005 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Specifications Fuse Block: Specifications Tighten the one screw that secures the junction block to the left instrument panel end bracket to 2.2 Nm (20 in. lbs.). Tighten the one screw that secures the junction block to the left instrument panel end bracket to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Specifications > Page 4648 Fuse Block: Locations Junction (Fuse) Block Junction Block Relay And Fuse Block Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4651 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4652 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4653 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4654 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4655 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4656 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4657 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4658 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4659 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4660 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4661 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4662 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4663 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4664 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4665 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4666 Fuse Block: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4667 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4668 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4669 Fuse Block: Connector Views 8w-12-2 Junction Block (Front View) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4670 8w-12-3 Junction Block (Rear View) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4671 8w-12-4 Fuses Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4672 8w-11-002 Fuse Block Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4673 Fuse Block: Electrical Diagrams Fuse Block 8w-11-003 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4674 8w-11-004 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4675 8w-11-005 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Junction Block Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4676 8w-12-5 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4677 8w-12-6 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4678 8w-12-7 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4679 8w-12-8 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4680 8w-12-9 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4681 8w-12-10 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4682 8w-12-11 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4683 8w-12-12 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4684 8w-12-13 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4685 8w-12-14 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4686 8w-12-15 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4687 8w-12-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4688 Fuse Block: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO 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 AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4689 Fuse Block: Description and Operation DESCRIPTION Junction Block Junction Block An electrical Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. 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 junction block fuses. 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 label to ensure proper fuse identification. The JB combines the functions previously provided by a separate fuseblock module and relay center, 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. 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. 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). Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. The fuses, circuit breakers, and relays are available for service replacement. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or if the JB housing is faulty or damaged, the entire JB unit must be replaced. Relay And Fuse Block An additional relay and fuse block is used on this model. 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. 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 Junction Block (JB) or the Power Distribution Center (PDC). Relay And Fuse Block Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4690 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 is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. The relay and fuse block has cavities for up to four additional blade-type mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. The fuses, flasher and relays are available for service replacement. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Junction Block Replacement Fuse Block: Service and Repair Junction Block Replacement WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO 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 AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. Fuse Access Panel Remove/Install 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. Reaching through the instrument panel fuse access panel opening, remove the one screw that secures the junction block to the left instrument panel end bracket. 4. Remove the steering column opening cover from the instrument panel. Refer to Steering Column Opening Cover/Service and Repair of Instrument Panel Systems for the procedures. 5. Reach through the outboard side of the instrument panel steering column opening to access the junction block. Junction Block Remove/Install 6. Disconnect all of the wire harness connectors from the connector receptacles on the back of the junction block. 7. Still reaching through the instrument panel steering column opening, remove the relay and fuse block from the junction block. 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. 8. Still reaching through the outboard side of the instrument panel steering column opening, remove the one screw that secures the junction block to the left instrument panel end bracket. 9. Remove the junction block from the left instrument panel end bracket. INSTALLATION 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 old JB to the proper cavities of the new JB. 1. Position the junction block onto the left instrument panel end bracket. 2. 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.). 3. Install the relay and fuse block onto the junction block by engaging its mounting slots with the tabs on the junction block. 4. Reconnect all of the wire harness connectors to the connector receptacles on the back of the junction block. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Junction Block Replacement > Page 4693 5. Install the steering column opening cover onto the instrument panel. Refer to Steering Column Opening Cover/Service and Repair of Instrument Panel Systems for the procedures. 6. Reaching through the instrument panel fuse access panel opening, 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Junction Block Replacement > Page 4694 Fuse Block: Service and Repair Relay and Fuse Block Replacement 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 if 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 AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the dash panel. Refer to Instrument Panel Assembly in Instrument Panel Systems for the procedures. 3. Disconnect each of the instrument panel wire harness connectors. 4. Remove all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. 5. Disengage each of the retainers that secure the instrument panel wire harness to the instrument panel components. 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. 7. Remove the relay and fuse block and the instrument panel wire harness from the instrument panel as a unit. INSTALLATION 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 old relay and fuse block to the proper cavities of the new relay and fuse block. 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. 3. Engage each of the retainers that secure the instrument panel wire harness to the instrument panel components. 4. Install all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. 5. Reconnect each of the instrument panel wire harness connectors. 6. Install the instrument panel assembly onto the dash panel. 7. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Specification Revisions Alignment: Technical Service Bulletins Steering/Suspension - Alignment Specification Revisions NUMBER: 26-12-98D GROUP: Miscellaneous DATE: December, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1999 Durango Service Manual - Publication Number 81-370-9116 DESCRIPTION OF CHANGES Revision to the wheel alignment specifications Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Specification Revisions > Page 4707 2-4 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Specification Revisions > Page 4708 Alignment: Technical Service Bulletins Alignment - Specification Correction NO: 02-11-98 GROUP: Suspension DATE: Oct. 30, 1998 SUBJECT: Alignment Specifications MODELS: 1999 (AN) Dakota 1999 (DN) Durango DISCUSSION: The alignment specifications identified in the 1999 Dakota Service Manual (Publication No. 81-370-9110), page 2-4 and in the 1999 Durango Service Manual (Publication No. 81-370-9116), page 2-4 have been changed. The charts identify the revised alignment specifications. In addition, the charts also identify the alignment specifications for the Dakota R/T. All changes to the Service Manual Alignment Specifications are highlighted with **Asterisks**. The specifications listed in the 1999 Dakota and Durango Service Manuals should no longer be used. Service Manual revision pages for the new alignment specifications will be available soon. Please make a note in these publications to refer to this Technical Service Bulletin until the revised pages Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Specification Revisions > Page 4709 are available. POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 4710 Alignment: Specifications The content of this article reflects changes called for in TSB 26-12-98. CASTER: Individual Side ..................................................................................................................................... ......................................................... +3.31° ± 1.0° Max RH/LH Difference ........................................ ..................................................................................................................................................... 0.50° CAMBER: Individual Side ..................................................................................................................................... ....................................................... +0.38° ± 0.50° Max RH/LH Difference ........................................ ..................................................................................................................................................... 0.50° TOTAL TOE: Individual Side ..................................................................................................................................... ....................................................... +0.10° ± 0.10° Max RH/LH Difference ........................................ .......................................................................................................................................................... 0° THRUST ANGLE: Standard .............................................................................................................................................. ................................................................. 0° ± 0.4° NOTE: All alignment specifications are in degrees. NOTE: For ride height adjustment and specifications see Service and Repair / Suspension Height. See: Service and Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 4711 Alignment: Description and Operation Wheel Alignment Measurements 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. 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 toe 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. 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. Refer to Maintenance for the recommended maintenance schedule. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 4712 Suspension And Steering System Diagnosis - Part 1 Of 2 Suspension And Steering System Diagnosis - Part 2 Of 2 SUSPENSION AND STEERING SYSTEM DIAGNOSIS Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 4713 Alignment: Testing and Inspection Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart for additional information. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Suspension Height Alignment: Service and Repair Suspension Height 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. HEIGHT MEASUREMENT 1. Jounce the front of the vehicle. Height Measurements 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). HEIGHT ADJUSTMENT 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Suspension Height > Page 4716 Alignment: Service and Repair Wheel Alignment CAMBER AND CASTER ADJUSTMENT Caster & Camber Adjustment-Typical Camber and caster angle adjustments involve changing the position of the upper suspension arm pivot bar. 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. The caster angle should be adjusted to preferred specification. NOTE: 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. CAMBER Move the front of the pivot bar in or out. This will change the camber angle significantly and caster angle slightly. The camber angle should be adjusted to preferred specification. After adjustment is made tighten the pivot bar nuts to proper torque specification. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Suspension Height > Page 4717 Toe Adjustment 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.). 5. Verify the specifications 6. Turn off engine. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Drag Link <--> [Center Link] > Component Information > Specifications Drag Link: Specifications Idler Arm Nut ....................................................................................................................................... .................................................... 88 Nm (65 ft. lbs.) Pitman Arm Nut ................................................. ....................................................................................................................................... 88 Nm (65 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Drag Link <--> [Center Link] > Component Information > Specifications > Page 4722 Drag Link: Service and Repair REMOVAL 1. Remove the outer and inner tie rod ends from the center link. 2. Remove cotter pins and nuts from the idler arm and pitman arm. 3. Separate the idler arm and pitman arm from the center link with Puller C-3894-A. 4. Remove center link. INSTALLATION 1. Install the center link on the pitman arm and idler arm. 2. Tighten the pitman arm nut to 88 Nm (65 ft. lbs.). Install new cotter pin. 3. Tighten the idler arm nut to 88 Nm (65 ft. lbs.). Install new cotter pin. 4. Install the inner and outer tie rod ends on the center link. 5. Set toe pattern, refer to Suspension. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair Front Steering Knuckle: Technical Service Bulletins Front Caliper Mounting/Steering Knuckle Thread Repair NUMBER: 05-03-99 GROUP: Brakes EFFECTIVE DATE: Apr. 23, 1999 SUBJECT: Front Brake Caliper Mounting To Steering Knuckle Thread Repair OVERVIEW: This bulletin involves repair of the threads on the steering knuckle or brake caliper mounting adapter that are used to install and retain the front brake caliper housing in its correct operating location. MODELS: 1986 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango DISCUSSION: A Brake Knuckle Thread Repair Kit has been developed to repair stripped threads on the front brake caliper mounting attachment making it no longer necessary to replace the front steering knuckle/brake caliper mounting adapter when encountering stripped threads. The following information provides the repair procedure for using the Brake Knuckle Thread Repair Kit. DIAGNOSIS: 1. Place the vehicle on an appropriate hoist. 2. Remove the front tire/wheel assembly. 3. Remove the brake caliper housing assembly by loosening the mounting bolts. NOTE: IF HIGH TORQUE IS ENCOUNTERED DURING THE MOUNTING BOLT REMOVAL, IT IS LIKELY THAT THREAD DAMAGE WILL OCCUR OR HAS OCCURRED. 4. Remove the caliper housing assembly and hang the housing on the frame of the vehicle using an appropriate wire hanger. NOTE: DO NOT ALLOW THE CALIPER HOUSING TO HANG BY ITSELF FROM THE BRAKE HOSE AS DAMAGE TO THE HOSE MAY RESULT. 5. If the vehicle has a bolt-on brake caliper mounting adapter, remove the adapter. If the brake caliper mounts directly to the steering knuckle, remove retainers on the wheel studs and remove the rotor. 6. Inspect the mounting bolts and knuckle threads for damage. If either is damaged, it is likely that damage to the other has occurred as well. If damage has occurred to the threads in the form of knicks, thread pulling, or cross-threading, perform the Repair Procedure. PARTS REQUIRED: AR (1) 05016156AA Insert, Heli-Coil, M9 X 1.25 AR (1) 04886075AA Bolts, Caliper Housing Mounting EQUIPMENT REQUIRED: AR (1) 05016155AA Kit, Brake Knuckle Thread Repair Includes: 23/64 Drill Bit M9 X 1.25 Tap Heli-Coil Installation Tool Heli-Coil Tang Break-Off Rod (25) M9 X 1.25 Stainless Steel Heli-Coils REPAIR PROCEDURE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair > Page 4727 1. Using the 23/64 in. drill, drill through the brake caliper mounting attachment hole keeping the drill perpendicular to the knuckle. 2. Using the M9 X 1.25 tap, tap the drilled hole ensuring to tap the hole entirely through. 3. Install a Heli-Coil insert onto the installation tool (tool number 3747-9). Be sure the tang is properly engaged into the driving contour of the tool. 4. Install the Heli-Coil into the drilled/tapped hole by rotating the tool and exerting slight pressure onto the tool/Heli-Coil and into the drilled/tapped hole. Continue to rotate the tool until the insert is located 1/4 to 1/2 turn below the steering knuckle surface. 5. Back the Heli-Coil installation tool out of the installed Heli-Coil. Then, remove the tang from the Heli-Coil by breaking the tang off using the tang break-off tool. Place the break-off tool into the assembled insert until it rests on the Heli-Coil tang. Holding the tool squarely, strike the tool sharply with a hammer. 6. If the vehicle has a bolt-on brake caliper mounting adapter, install the adapter. Refer to the appropriate Service Manual for information regarding proper brake caliper adapter mounting information. If the brake caliper mounts directly to the steering knuckle, install the rotor. 7. Install the caliper using new mounting bolts p/n 04886075AA in any location that had a Heli-Coil installed. Tighten the bolts to 30 - 35 N.m (22-26 ft. lbs.). 8. Install the tire/wheel assembly. 9. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-93 Brake Caliper Mounting Support Thread Repair, Left Side 0.4 Hrs. 05-80-20-94 Brake Caliper Mounting Support Thread Repair, Right Side 0.4 Hrs. 05-80-20-50 Brake Caliper Mounting Support Thread Repair, Each Additional Same Side 0.1 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 4728 Front Steering Knuckle: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper, rotor, shield and ABS wheel speed sensor if equipped. 4. Remove front driveshaft. Tie Rod End 5. Remove tie rod end cotter pin and nut. Separate the tie rod from the knuckle with Remover MB-991113. 6. Support the lower suspension arm with a hydraulic jack and raise the jack to unload the rebound bumper. Upper Ball Joint 7. Remove the upper ball joint cotter pin and nut. Separate the ball joint from the knuckle with Remover MB-991113. CAUTION: When installing Remover MB-991113 to separate the ball joint, be careful not to damage the ball joint seal. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 4729 Lower Ball Joint 8. Remove the lower ball joint cotter pin and nut. Separate the ball joint from the knuckle with Remover C-4150A and remove the knuckle. 9. Remove the hub/bearing from the steering knuckle. INSTALLATION 1. Install the hub/bearing to the steering knuckle and tighten the bolts to 166 Nm (123 ft. lbs.). NOTE: When installing hub/bearing with ABS brakes, position the speed sensor opening towards the front of the vehicle. 2. Install the knuckle onto the upper and lower ball joint. CAUTION: The ball joint stud tapers must be CLEAN and DRY before installing the knuckle. Clean the stud tapers with mineral spirits to remove dirt and grease. 3. Install the upper and lower ball joint nuts. Tighten the upper ball joint nut to 81 Nm (60 ft. lbs.) and the lower ball joint nut to 183 Nm (135 ft. lbs.) then install cotter pins. Grease the lower ball joint. 4. Remove the hydraulic jack from the lower suspension arm. 5. Install the tie rod end and tighten the nut to 88 Nm (65 ft. lbs.). Install the cotter pin. 6. Install the front driveshaft. 7. Install the ABS wheel speed sensor if equipped and brake shield, rotor and caliper. 8. Install the wheel and tire assembly. 9. Remove support and lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications Idler Arm: Specifications To Frame Nuts ..................................................................................................................................... ................................................. 136 Nm (110 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 4733 Idler Arm: Service and Repair REMOVAL 1. Remove the cotter pin and nut from the idler arm at the center link. 2. Separate idler arm from the center link with Puller C-3894-A. 3. Remove nuts from the stud plate and remove idler arm. INSTALLATION 1. Position the idler arm on the stud plate and tighten the nuts to 136 Nm (110 ft. lbs.). 2. Install idler arm to the center link and tighten nut to 88 Nm (65 ft. lbs.). Install a new cotter pin. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Service and Repair Pitman Arm: Service and Repair To remove the pitman arm the steering gear must be removed from the vehicle. Refer to steering gear removal for the procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4742 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4743 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4744 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Power steering fluid Power steering capacities are dependant on engine/chassis options as well as steering gear/cooler options. Depending on type ans size of internal cooler, length and inside diameter of lines, or use of an auxiliary cooler, this capacity may vary. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 4747 Power Steering Fluid: Fluid Type Specifications All models Mopar Power Steering Fluid or equivalent Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Page 4748 Power Steering Fluid: Service Precautions DO NOT use automatic transmission fluid instead of Mopar Power Steering Fluid. System damage can result. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications Power Steering Fluid Cooler: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 41 Nm (30 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair Power Steering Fluid Reservoir: Service and Repair DISASSEMBLY 1. Remove pump assembly. Pump Reservoir 2. Remove mounting studs and pressure fitting. Rock reservoir by hand or use a soft face mallet and remove reservoir. 3. Remove O-ring seals from housing and discard. Flow Control Valve 4. Remove flow control valve and spring from housing. ASSEMBLY NOTE: Clean all parts before installation. Lubricate new O-ring seals with MOPAR Power Steering Fluid or an equivalent product. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Page 4755 1. Install flow control valve and spring. 2. Install new O-ring seals on housing and install reservoir, 3. Install mounting studs and tighten to 48 Nm (35 ft. lbs.). 4. Install fitting in flow control valve bore tighten to 75 Nm (55 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Pressure Line ...................................................................................................................................... ...................................................... 35 Nm (25 ft. lbs.) Return Line ..................................................... .......................................................................................................................................... 35 Nm (25 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4763 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4764 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4765 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Pump Bracket Bolts ............................................................................................................................. ..................................................... 41 Nm (30 ft. lbs.) Pump Mounting Bolts ....................................... ........................................................................................................................................ 41 Nm (30 ft. lbs.) Reservoir Bolts ............................................................................................................................ ............................................................. 48 Nm (35 ft. lbs.) Flow Control Valve ................................... ............................................................................................................................................... 75 Nm (55 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 4768 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Relief Pressure ± 50 ............................................................................................................................ ................................................. 10342 kPa (1500 psi) Flow Rate At 1500 RPM ................................. ................................................................................................................................................ 2.4 2.8 GPM Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 4769 Power Steering Pump: Description and Operation All vehicles use a P-Series pump. Hydraulic pressure is provided for the power steering gear by the belt driven power steering pump. The power steering pump is a constant flow rate and displacement, vane-type pump. 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. The oil cooler is mounted to the front of the engine under the pump. NOTE: Power steering pumps are not interchangeable with pumps installed on other vehicles. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 4770 Pump Leakage Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Initial Operation Power Steering Pump: Service and Repair 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. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two 2. minutes. 2. Start the engine and let run for a few seconds then turn engine off. 3. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 4. Raise the front wheels off the ground. 5. Slowly turn the steering wheel right and left, lightly contacting the wheel stops at least 20 times. 6. Check the fluid level add if necessary. 7. Lower the vehicle, start the engine and turn the steering wheel slowly from lock to lock. 8. Stop the engine and check the fluid level and refill as required. 9. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Initial Operation > Page 4773 Power Steering Pump: Service and Repair Power Steering Pump Pulley Replacement DISASSEMBLY 1. Remove pump assembly. 2. Remove pulley from pump with Puller C-4333. ASSEMBLY 1. Replace pulley if bent, cracked, or loose. Fig. 6 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 inch) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Initial Operation > Page 4774 Power Steering Pump: Service and Repair Power Steering Pump Removal and Installation REMOVAL 1. Remove the serpentine drive belt. 2. Clamp the fluid return hose and disconnect the hoses from the power steering pump. Cap the fittings. 3. Remove battery ground cable and bracket bolts. 4. Remove the pump assembly. 5. Remove the pump pulley. This will allow access to the pump attaching screws. 6. Remove the pump bracket bolts and remove the bracket. INSTALLATION 1. Install the bracket on the pump and tighten bolts to 41 Nm (30 ft. lbs.). 2. Install the pump pulley, refer to Pump Pulley Installation. 3. Install pump assembly on the engine block and tighten the bolts to 41 Nm (30 ft. lbs.). 4. Install the battery ground wire and tighten nut to 41 Nm (30 ft. lbs.). 5. Connect the fluid hoses to the pump. 6. Install the serpentine drive belt refer to Cooling System. 7. Fill the reservoir with power steering fluid, refer to Power Steering Pump Initial-Operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Tools and Equipment > Power Steering System Analyzer 6815 Analyzer Set, Power Steering Flow/Pressure 6815 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Tools and Equipment > Power Steering System Analyzer 6815 > Page 4777 Adapters, Power Steering Flow/Pressure Tester 6893 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Tools and Equipment > Power Steering System Analyzer 6815 > Page 4778 Puller C-4333 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Tools and Equipment > Power Steering System Analyzer 6815 > Page 4779 Installer, Power Steering Pulley C-4063B Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming Disconnect and isolate the battery negative cable. If the airbag module has not been deployed, wait two minutes for the system capacitor to discharge before further service. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 4785 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming 16-Way Data Link Connector - Typical 1. Make sure no one is in the vehicle. 2. Connect the negative battery terminal. 3. Connect the DRB scan tool to the 16-way data link wire harness connector. The connector is located on the driver side lower edge of the instrument panel, outboard of the steering column. 4. Turn the ignition switch to the ON position. Exit the vehicle with the DRB. Use the latest version of the proper DRB cartridge. 5. Erase the stored DTC data. If any problems remain, the stored DTC data will not erase. 6. With the ignition switch still in the ON position, make sure nobody is in the vehicle. 7. From outside of the vehicle (away from the airbag modules in case of an accidental deployment) turn the ignition switch to the OFF position for about 10 seconds, and then back to the ON position. Observe the airbag indicator lamp in the instrument cluster. It should light for six to 8 seconds, and then go out. This indicates that the airbag system is functioning normally. NOTE: If the airbag indicator lamp fails to light, or lights and stays on, there is an airbag system malfunction. Refer to the proper Diagnostic Procedures to diagnose the problem. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key-In Ignition Switch <--> [Key Reminder Switch] > Component Information > Description and Operation Key-In Ignition Switch: Description and Operation The key-in ignition switch is integral to the ignition switch, which is mounted on the right side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition lock cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition lock cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key-In Ignition Switch <--> [Key Reminder Switch] > Component Information > Description and Operation > Page 4789 Key-In Ignition Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. Remove the steering column shrouds. Unplug the key-in ignition switch wire harness connector from the ignition switch. 2. Check for continuity between the key-in ignition switch sense and ground terminals of the key-in ignition switch. There should be continuity with the key in the ignition lock cylinder, and no continuity with the key removed from the ignition lock cylinder. If OK, go to Step 3. If not OK, replace the faulty ignition switch assembly. 3. Open the driver door. Check for continuity between the ground circuit cavity of the key-in ignition 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 the driver door ajar switch as required. 4. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the procedures. Unplug the 14-way CTM wire harness connector. Close the driver door. Check for continuity between the key-in ignition switch sense circuit cavity of the CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the short circuit as required. 5. Check for continuity between the key-in ignition switch sense circuit cavities of the key-in ignition switch wire harness connector and the 14-way CTM wire harness connector. There should be continuity. If OK, test the CTM as described. If not OK, repair the open circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Locations Steering Column Opening Cover Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Locations > Page 4793 Steering Column Cover: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Procedures Steering Column Cover: Procedures WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. Steering Column Opening Cover Remove/Install 2. Remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. 3. Using a trim stick or another suitable wide fiat-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 the snap clip retainers from the receptacles in the instrument panel. 4. Remove the steering column opening cover from the instrument panel. INSTALLATION 1. Position the steering column opening cover to the instrument panel. 2. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel. 3. 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 and tighten the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Tighten the screws to 2.2 N.m (20 in. lbs.). 5. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Procedures > Page 4796 Steering Column Cover: Removal and Replacement 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Procedures > Page 4797 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications Steering Gear: Specifications GENERAL SPECIFICATIONS: Gear Ratio ........................................................................................................................................... ................................................................. 16 - 13:1 Worm Shaft Bearing Preload .......................................................................................................................................... 0.56 - 1.36 Nm (5 - 12 inch lbs.) Pitman Shaft Overcenter: Rotating Torque [1] .................................................................................................................................................... 0.45 - 0.90 Nm (4 - 8 inch lbs.) TIGHTENING TORQUE: Gear to Frame Bolts ............................................................................................................................ .................................................. 88 Nm (65 ft. lbs.) Pitman Shaft Nut ................................................. .............................................................................................................................. 251 Nm (185 ft. lbs.) Adjustment Cap Locknut .............................................................................................................. ...................................................... 108 Nm (80 ft. lbs.) Adjustment Screw Locknut ........................... ........................................................................................................................................ 49 Nm (36 ft. lbs.) Rack Piston Plug ......................................................................................................................... ........................................................ 102 Nm (75 ft. lbs.) Side Cover Bolts ......................................... .......................................................................................................................................... 61 Nm (45 ft. lbs.) Return Guide Clamp Bolt ......................................................................................................... ........................................................... 5 Nm (48 inch lbs.) [1]: Add Preload Rotating Torque. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 4801 Steering Gear: Description and Operation Recirculating Ball Gear-Typical A recirculating ball type gears is used on this vehicle. The gear has a variable ratio of 16-13 to 1. The gear acts as a rolling thread between the worm shaft and rack piston. The worm shaft is supported by a thrust bearing at the lower end and a bearing assembly at the upper end. When the worm shaft is turned the rack piston moves. The rack piston teeth mesh with the pitman shaft. Turning the worm shaft turns the pitman shaft, which turns the steering linkage. CAUTION: Components attached with a nut and cotter pin must be first torqued to specification. If the slot in the nut does not line up with the coffer pin hole, tighten nut until it is aligned. Never loosen the nut to align the coffer pin hole. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 4802 Power Steering Gear Leakage Diagnosis Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 4803 Steering Gear: Adjustments CAUTION: Steering gear must be adjusted in the proper order. If adjustments are not performed in order, gear damage and improper steering response may result. NOTE: Adjusting the steering gear in the vehicle is not recommended. Remove gear from the vehicle and drain the fluid. Then mount gear in a vise to perform adjustments. WORM THRUST BEARING PRELOAD 1. Mount the gear carefully into a vise. CAUTION: Do not overtighten the vise on the gear case. This may affect the adjustment 2. Remove adjuster plug locknut. 3. Rotate the stub shaft back and forth with a 12 point socket to drain the remaining fluid. 4. Turn the adjuster in with Spanner Wrench C-4381. Tighten the plug and thrust bearing in the housing until firmly bottomed in the housing about 34 Nm (25 ft. lbs.). 5. Place an index mark on the housing even with one of the holes in adjuster plug. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 4804 6. Measure back (counterclockwise) 10 mm (0.40 inch) and mark housing. 7. Rotate adjustment cap back (counterclockwise) with spanner wrench until hole is aligned with the second mark. 8. Install and tighten locknut to 108 Nm (80 ft. lbs.). Be sure adjustment cap does not turn while tightening the locknut. OVER-CENTER NOTE: Before performing this procedure, the worm bearing preload adjustment must be performed. 1. Rotate the stub shaft with a 12 point socket from stop to stop and count the number of turns. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 4805 Steering Gear Centered 2. Starting at either stop, turn the stub shaft back 1/2 the total number of turns. This is the center of the gear travel. Checking Over-center Rotation Torque 3. Place the torque wrench in the vertical position on the stub shaft. Rotate the wrench 45 degrees each side of the center and record the highest rotational torque in this range. This is the Over-Center Rotating Torque. NOTE: The stub shaft must rotate smoothly without sticking or binding. 4. Rotate the stub shaft between 90° and 180° to the left of center and record the left off-center preload. Repeat this to the right of center and record the right off-center preload. The average of these two recorded readings is the Preload Rotating Torque. 5. The Over-Center Rotating Torque should be 0.45 - 0.9 Nm (4 - 8 inch lbs.) higher than the Preload Rotating Torque. 6. If an adjustment to the Over-Center Rotating Torque is necessary, first loosen the adjuster lock nut. Then turn the pitman shaft adjuster screw back (COUNTERCLOCKWISE) until fully extended, then turn back in (CLOCKWISE) one full turn. 7. Remeasure Over-Center Rotating Torque. If necessary turn the adjuster screw and repeat measurement until correct Over-Center Rotating Torque is reached. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 4806 NOTE: To increase the Over-Center Rotating Torque turn the screw CLOCKWISE. 8. Prevent the adjuster screw from turning while tightening adjuster lock nut. Tighten the adjuster lock nut to 49 Nm (36 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement Steering Gear: Service and Repair Steering Gear Replacement REMOVAL 1. Place the front wheels in the straight ahead position with the steering wheel centered. 2. Disconnect and cap the fluid lines from the steering gear. Steering Gear Coupler 3. Remove the lower shaft coupler bolt and slide coupler off the gear. 4. Raise and support the vehicle. 5. Remove the cotter pin and nut from the pitman arm ball stud. 6. Separate the pitman arm from the center link with Puller C-3894-A. 7. Remove splash shield under cooling module. Steering Gear Mounting Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 4809 Steering Gear Removal 8. Remove the steering gear mounting bolts. Remove steering gear from the vehicle by lowering it through the opening between the cooling module and the frame crossmember. Pitman Arm 9. Remove pitman arm from the gear with Remover C-4150A. INSTALLATION NOTE: Gear mounting bolts must be replaced or use Mopar Lock 'N Seal or Loctite(R) 242 on existing bolts. 1. Align and install the pitman arm on gear and tighten to 231 Nm (185 ft. lbs.). 2. Install steering gear on the frame rail and tighten the bolts to 88 Nm (65 ft. lbs.). 3. Install pitman arm ball stud in center link and tighten nut to 88 Nm (65 ft. lbs.). Install new cotter pin. 4. Remove support and lower vehicle. 5. Install shaft coupler on the steering gear and tighten coupler bolt to 49 Nm (36 ft. lbs.). 6. Connect fluid hoses to steering gear and tighten to 35 Nm (25 ft. lbs.). 7. Fill power steering pump, refer to Power Steering Pump-Initial Operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 4810 Steering Gear: Service and Repair Overhaul Housing End Plug DISASSEMBLY 1. Unseat and remove retaining ring from groove with a punch through the hole in the end of the housing. 2. Slowly rotate stub shaft with 12 point socket COUNTER-CLOCKWISE to force the end plug out from housing. CAUTION: Do not turn stub shaft any further than necessary. The rack piston balls will drop out of the rack piston circuit if the stub shaft is turned too far. 3. Remove O-ring from the housing. ASSEMBLY Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 4811 1. Lubricate O-ring with power steering fluid and install into the housing. 2. Install end plug by tapping the plug lightly with a plastic mallet into the housing. 3. Install retaining ring so one end of the ring covers the housing access hole. Pitman Shaft/Seals/Bearing DISASSEMBLY 1. Clean exposed end of pitman shaft and housing with a wire brush. Side Cover And Pitman Shaft 2. Remove preload adjuster nut. 3. Rotate the stub shaft with a 12 point socket from stop to stop and count the number of turns. 4. Center the stub shaft by rotating it from the stop 1/2 of the total amount of turns. 5. Remove side cover bolts and remove side cover, gasket and pitman shaft as an assembly. NOTE: The pitman shaft will not clear the housing if it is not centered. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 4812 6. Remove pitman shaft from the side cover. Pitman Shaft Seals & Bearing 7. Remove dust seal from the housing with a seal pick. CAUTION: Use care not to score the housing bore when prying out seals and washer. 8. Remove retaining ring with snap ring pliers. 9. Remove washer from the housing. 10. Remove oil seal from the housing with a seal pick. 11. Remove pitman shaft bearing from housing with a bearing driver and handle. ASSEMBLY 1. Install pitman shaft bearing into housing with a bearing driver and handle. 2. Coat the oil seal and washer with special grease supplied with the new seal. 3. Install the oil seal with a driver and handle. 4. Install backup washer. 5. Install the retainer ring with snap ring pliers. 6. Coat the dust seal with special grease supplied with the new seal. 7. Install dust seal with a driver and handle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 4813 8. Install pitman shaft to side cover by screwing shaft in until it fully seats to side cover. 9. Install preload adjuster nut. Do not tighten nut until after Over-Center Rotation Torque adjustment has been made. 10. Install gasket to side cover and bend tabs around edges of side cover. 11. Install pitman shaft assembly and side cover to housing. 12. Install side cover bolts and tighten to 60 Nm (44 ft. lbs.). 13. Perform over-center rotation torque adjustment. Spool Valve DISASSEMBLY 1. Remove lock nut. 2. Remove adjuster nut with Spanner Wrench C-4381. 3. Remove thrust support assembly out of the housing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 4814 4. Pull stub shaft and valve assembly from the housing. Stub Shaft 5. Remove stub shaft from valve assembly by lightly tapping shaft on a block of wood to loosen shaft. Then disengage stub shaft pin from hole in spool valve and separate the valve assembly from stub shaft. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 4815 6. Remove spool valve from valve body by pulling and rotating the spool valve from the valve body. 7. Remove spool valve O-ring and valve body teflon rings and O-rings underneath the teflon rings. 8. Remove the O-ring between the worm shaft and the stub shaft. ASSEMBLY NOTE: Clean and dry all components, then lubricate with power steering fluid. 1. Install spool valve spool O-ring. 2. Install spool valve in valve body by pushing and rotating. Hole in spool valve for stub shaft pin must be accessible from opposite end of valve body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 4816 3. Install stub shaft in valve spool and engage locating pin on stub shaft into spool valve hole. NOTE: Notch in stub shaft cap must fully engage valve body pin and seat against valve body shoulder. 4. Install O-rings and teflon rings over the O-rings on valve body. 5. Install O-ring into the back of the stub shaft cap. 6. Install stub shaft and valve assembly in the housing. Line up worm shaft to slots in the valve assembly. 7. Install thrust support assembly. NOTE: The thrust support is serviced as an assembly. If any component of the thrust support is damaged the assembly must be replaced. 8. Install adjuster nut and lock nut. 9. Adjust Thrust Bearing Preload and Over-Center Rotating Torque. Rack Piston and Worm Shaft DISASSEMBLY 1. Remove housing end plug. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 4817 2. Remove rack piston plug. 3. Remove side cover and pitman shaft. 4. Turn stub shaft COUNTERCLOCKWISE until the rack piston begins to come out of the housing. 5. Insert Arbor C-4175 into bore of rack piston and hold tool tightly against worm shaft. 6. Turn the stub shaft with a 12 point socket COUNTERCLOCKWISE, this will force the rack piston onto the tool and hold the rack piston balls in place. 7. Remove the rack piston and tool together from housing. 8. Remove tool from rack piston. 9. Remove rack piston balls. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 4818 Rack Piston 10. Remove clamp bolts, clamp and ball guide. 11. Remove teflon ring and O-ring from the rack piston. 12. Remove the adjuster lock nut and adjuster nut from the stub shaft. 13. Pull the stub shaft with the spool valve and thrust support assembly out of the housing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 4819 14. Remove the worm shaft from the housing. ASSEMBLY NOTE: Clean and dry all components and lubricate with power steering fluid. 1. Check for scores, nicks or burrs on the rack piston finished surface. Slight wear is normal on the worm gear surfaces. 2. Install O-ring and teflon ring on the rack piston. Installing Balls In Rack Piston 3. Install worm shaft in the rack piston and align worm shaft spiral groove with rack piston ball guide hole. CAUTION: The rack piston balls must be installed alternately into the rack piston and ball guide. This maintains worm shaft preload. There are 12 black balls and 12 silver (Chrome) balls. The black balls are smaller than the silver balls. 4. Lubricate and install rack piston balls through return guide hole while turning worm shaft COUNTERCLOCKWISE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 4820 5. Install remaining balls in guide using grease to hold the balls in place. 6. Install the guide onto rack piston and install clamp and clamp bolts. Tighten bolts to 58 Nm (43 ft. lbs.). 7. Insert Arbor C-4175 into bore of rack piston and hold tool tightly against worm shaft. 8. Turn the worm shaft COUNTERCLOCKWISE while pushing on the arbor. This will force the rack piston onto the arbor and hold the rack piston balls in place. 9. Install the races and thrust bearing on the worm shaft and install shaft in the housing. 10. Install the stub shaft with spool valve, thrust support assembly and adjuster nut in the housing. 11. Install the rack piston and arbor tool into the housing. 12. Hold arbor tightly against worm shaft and turn stub shaft CLOCKWISE until rack piston is seated on worm shaft. 13. Install pitman shaft and side cover in the housing. 14. Install rack piston plug and tighten to 150 Nm (111 ft. lbs.). 15. Install housing end plug. 16. Adjust worm shaft thrust bearing preload and over-center rotating torque. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Page 4821 Steering Gear: Tools and Equipment Special Tool C-4381 Remover, Pitman Arm C-4150A Special Tool C-4175 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications Steering Wheel: Specifications Retaining Nut ....................................................................................................................................... ..................................................... 47 Nm (35 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Service and Repair Tie Rod Boot: Service and Repair REMOVAL 1. Remove steering gear. 2. Loosen the jam nut then remove the tie rod end and jam nut. Boot Seal 3. Remove the outer clamp from the rubber boot. 4. Remove the boot inner clamp. 5. Mark the breather tube location on steering ear heron 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. 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 and the snorkel clamp. 5. Install outer clamp on the inner tie rod. 6. Install the jam nut and the tie rod end. 7. Install steering gear. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications OUTER TIE ROD Knuckle Nut ......................................................................................................................................... ..................................................... 88 Nm (65 ft. lbs.) Jam Nut ............................................................ ......................................................................................................................................... 75 Nm (55 ft. lbs.) INNER TIE ROD Inner Tie Rod ....................................................................................................................................... ..................................................... 68 Nm (50 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod End Tie Rod End: Service and Repair Outer Tie Rod End REMOVAL 1. Remove the cotter pins and nuts at the steering knuckle. 2. Separate the tie rod ball stud from the knuckle with Remover MB-991113. 3. Loosen the jam nut and unthread the tie rod end from the tie rod. INSTALLATION 1. Thread the tie rod end onto the tie rod, to it's original position. 2. Install the tie rod ball stud to the steering knuckle. 3. Tighten the ball stud nut on the steering knuckle to 88 Nm (65 ft. lbs.). Install new cotter pin. 4. Tighten jam nut to 75 Nm (55 ft. lbs.). 5. Set wheel toe pattern. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod End > Page 4834 Tie Rod End: Service and Repair Inner Tie Rod End REMOVAL 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Remove outer tie rod end. 4. Remove inner tie rod end from the center link. INSTALLATION Center Link & Inner Tie Rod 1. Thread the inner tie rod end into the center link. 2. Tighten the inner tie rod end to 68 Nm (50 ft. lbs.). 3. Install the out tie rod end. 4. Install the tire and wheel assembly. 5. Remove support and lower the vehicle. 6. Set wheel toe pattern. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Lower Ball Joint Ball Joint: Specifications Lower Ball Joint Ball Joint Nut ....................................................................................................................................... ................................................. 183 Nm (135 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Lower Ball Joint > Page 4840 Ball Joint: Specifications Upper Ball Joint Ball Joint Nut ....................................................................................................................................... ..................................................... 81 Nm (60 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 NOTE: If the ball joint is equipped with a lubrication fitting, grease the joint then road test the vehicle before performing test. 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 surface 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 jounce/rebound bracket. 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 control arm. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint > Page 4843 Ball Joint: Testing and Inspection Upper Ball Joint 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 back side of the upper ball joint boss of the steering knuckle. 4. Grasp the top of the tire and pull outward, then zero the dial indicator. 5. Grasp the top of the tire and push inward and record the dial indicator reading. 6. If lateral movement is greater than 1.52 mm (0.060 inch), replace upper suspension arm. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 4844 Ball Joint: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Unload the torsion bar spring load by turning the adjuster bolt counterclockwise. 4. Remove the adjuster bolt, bearing, swivel and anchor from the torsion bar. NOTE: Leave the torsion bar in the lower control arm. 5. Remove the stabilizer bar retainer bolts and retainers from the lower suspension arms. Swivel the stabilizer bar away from the lower suspension arms. 6. Remove the shock absorber lower mounting bolt. 7. Remove the rear lower suspension arm mounting bolt and loosen the front bolt. 8. Remove axle hub cotter pin, lock nut, retaining nut and washer. 9. Remove the front driveshaft bolts from inner C/V joint flange. 10. Remove the front driveshaft. 11. Remove lower ball joint cotter pin and nut. Separate the ball joint from the knuckle with Remover C-4150A. 12. Turn the wheels all the way to the left when removing right ball joint. Turn the wheels all the way to the right when removing left ball joint. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 4845 Support The Knuckle 13. Support the knuckle with a jack stand and raise the jack up to gain access to the lower ball joint. 14. With a chisel remove the four stakes on the ball joint flange. NOTE: If equipped with Dana (R) ball joint remove snap-ring. 15. Remove the ball joint boot. Lower Ball Joint Removal 16. Remove the ball joint with Press C-4212F, Receiver 8345 and Driver C-4212-3. INSTALLATION Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 4846 Lower Ball Joint Installation 1. Install the ball joint with Press C-4212F and Driver 6758. 2. Install the ball joint boot. 3. Stake the ball joint flange in four places with a chisel and hammer. NOTE: If equipped with Dandy ball joint install snap-ring. 4. Insert the ball joint into the knuckle. Install and tighten the retaining nut to 183 Nm (135 ft. lbs.) and install a new cotter pin. 5. Lubricate the lower ball joint. 6. Install the front driveshaft. 7. Install the front driveshaft bolts to inner C/V joint flange. 8. Install axle hub washer, retaining nut, lock nut and cotter pin. 9. Install the rear lower suspension arm mounting bolt. 10. Install the shock absorber lower bolt and tighten to 108 Nm (80 ft. lbs.). 11. Install the torsion bar anchor, adjuster bolt, bearing and swivel. 12. Install the wheel and tire assembly. 13. Remove support and lower the vehicle. 14. Tighten the lower suspension arm mounting bolts at the frame brackets to: - Front Bolt 108 Nm (80 ft. lbs.) - Rear Bolt 190 Nm (140 ft. lbs.) 15. Pivot the stabilizer bar up to the lower suspension arm. Install the retainers and bolts and tighten to 34 Nm (25 ft. lbs.). 16. Adjust the front suspension height. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Specifications Control Arm: Specifications LOWER SUSPENSION ARM: Front Bolt ............................................................................................................................................. ............................................ 175 Nm (130 ft. lbs.) Rear Bolt ............................................................... .............................................................................................................................. 108 Nm (80 ft. lbs.) UPPER SUSPENSION ARM: Pivot Shaft Nuts ................................................................................................................................... ............................................. 167 Nm (130 ft. lbs.) Pivot Shaft Frame Bolts ....................................... ............................................................................................................................. 204 Nm (150 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower Control Arm Control Arm: Service and Repair Lower Control Arm REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove front driveshaft, refer to Differential & Driveline. 4. Remove torsion bar. 5. Remove shock absorber lower bolt. 6. Remove stabilizer bar. 7. Remove the cotter pin and nut from lower ball joint. Separate ball joint from the steering knuckle with Remover C-4150A. 8. Remove suspension arm pivot bolts and suspension arm from frame rail brackets. 9. Inspect lower ball joint seal and replace if damaged. Pry off old seal with screw driver if necessary. INSTALLATION 1. Install new lower ball joint seal by tapping on around the seal flange lightly with a hammer. 2. Position the lower suspension arm at the frame rail brackets. Install the pivot bolts and nuts. Tighten the nuts finger-tight. 3. Insert the ball joint into steering knuckle. Install and tighten the retaining nut to 183 Nm (135 ft. lbs.) and install a new cotter pin. CAUTION: The ball joint stud taper must be CLEAN and DRY before installing the knuckle. Clean the stud taper with mineral spirits to remove dirt and grease. 4. Install the torsion bar. 5. Install shock absorber lower bolt and tighten to 108 Nm (80 ft. lbs.). 6. Install the front driveshaft. Refer to Differential & Driveline. 7. Install the wheel and tire assembly. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower Control Arm > Page 4852 8. Remove support and lower the vehicle. 9. Install the stabilizer bar. 10. Tighten the lower suspension front pivot nut to 108 Nm (80 ft. lbs.). Tighten rear pivot bolt to 190 Nm (140 ft. lbs.). 11. Lubricate lower ball joint. 12. Adjust the front suspension height. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower Control Arm > Page 4853 Control Arm: Service and Repair Upper Control Arm REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake hose brackets from suspension arm. 4. Position hydraulic jack under lower suspension arm and raise jack to unload rebound bumper. 5. Remove shock absorber. 6. Remove the cotter pin and nut from upper ball joint. 7. Separate upper ball joint from the steering knuckle with Remover MB-991113. CAUTION: When installing Remover MB-991113 to separate the ball joint, be careful not to damage the ball joint seal. 8. Remove suspension arm pivot bar bolts and remove suspension arm. INSTALLATION 1. Position suspension arm pivot bar on mounting bracket. Install bolts and tighten (temporarily) to 136 Nm (100 ft. lbs.). 2. Insert ball joint in steering knuckle and tighten ball joint nut to 81 Nm (60 ft. lbs.) then install a new cotter pin. 3. Install shock absorber. NOTE: Upper shock nut must be replaced or use Mopar Lock 'N Seal or Loctite(R) 242 on existing nut. 4. Remove hydraulic jack. 5. Attach brake hose brackets to suspension arm. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower Control Arm > Page 4854 6. Tighten upper suspension arm pivot bolts to 204 Nm (150 ft. lbs.). 7. Install the wheel and tire assembly. 8. Remove support and lower vehicle. 9. Align front suspension. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair Front Steering Knuckle: Technical Service Bulletins Front Caliper Mounting/Steering Knuckle Thread Repair NUMBER: 05-03-99 GROUP: Brakes EFFECTIVE DATE: Apr. 23, 1999 SUBJECT: Front Brake Caliper Mounting To Steering Knuckle Thread Repair OVERVIEW: This bulletin involves repair of the threads on the steering knuckle or brake caliper mounting adapter that are used to install and retain the front brake caliper housing in its correct operating location. MODELS: 1986 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango DISCUSSION: A Brake Knuckle Thread Repair Kit has been developed to repair stripped threads on the front brake caliper mounting attachment making it no longer necessary to replace the front steering knuckle/brake caliper mounting adapter when encountering stripped threads. The following information provides the repair procedure for using the Brake Knuckle Thread Repair Kit. DIAGNOSIS: 1. Place the vehicle on an appropriate hoist. 2. Remove the front tire/wheel assembly. 3. Remove the brake caliper housing assembly by loosening the mounting bolts. NOTE: IF HIGH TORQUE IS ENCOUNTERED DURING THE MOUNTING BOLT REMOVAL, IT IS LIKELY THAT THREAD DAMAGE WILL OCCUR OR HAS OCCURRED. 4. Remove the caliper housing assembly and hang the housing on the frame of the vehicle using an appropriate wire hanger. NOTE: DO NOT ALLOW THE CALIPER HOUSING TO HANG BY ITSELF FROM THE BRAKE HOSE AS DAMAGE TO THE HOSE MAY RESULT. 5. If the vehicle has a bolt-on brake caliper mounting adapter, remove the adapter. If the brake caliper mounts directly to the steering knuckle, remove retainers on the wheel studs and remove the rotor. 6. Inspect the mounting bolts and knuckle threads for damage. If either is damaged, it is likely that damage to the other has occurred as well. If damage has occurred to the threads in the form of knicks, thread pulling, or cross-threading, perform the Repair Procedure. PARTS REQUIRED: AR (1) 05016156AA Insert, Heli-Coil, M9 X 1.25 AR (1) 04886075AA Bolts, Caliper Housing Mounting EQUIPMENT REQUIRED: AR (1) 05016155AA Kit, Brake Knuckle Thread Repair Includes: 23/64 Drill Bit M9 X 1.25 Tap Heli-Coil Installation Tool Heli-Coil Tang Break-Off Rod (25) M9 X 1.25 Stainless Steel Heli-Coils REPAIR PROCEDURE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair > Page 4859 1. Using the 23/64 in. drill, drill through the brake caliper mounting attachment hole keeping the drill perpendicular to the knuckle. 2. Using the M9 X 1.25 tap, tap the drilled hole ensuring to tap the hole entirely through. 3. Install a Heli-Coil insert onto the installation tool (tool number 3747-9). Be sure the tang is properly engaged into the driving contour of the tool. 4. Install the Heli-Coil into the drilled/tapped hole by rotating the tool and exerting slight pressure onto the tool/Heli-Coil and into the drilled/tapped hole. Continue to rotate the tool until the insert is located 1/4 to 1/2 turn below the steering knuckle surface. 5. Back the Heli-Coil installation tool out of the installed Heli-Coil. Then, remove the tang from the Heli-Coil by breaking the tang off using the tang break-off tool. Place the break-off tool into the assembled insert until it rests on the Heli-Coil tang. Holding the tool squarely, strike the tool sharply with a hammer. 6. If the vehicle has a bolt-on brake caliper mounting adapter, install the adapter. Refer to the appropriate Service Manual for information regarding proper brake caliper adapter mounting information. If the brake caliper mounts directly to the steering knuckle, install the rotor. 7. Install the caliper using new mounting bolts p/n 04886075AA in any location that had a Heli-Coil installed. Tighten the bolts to 30 - 35 N.m (22-26 ft. lbs.). 8. Install the tire/wheel assembly. 9. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-93 Brake Caliper Mounting Support Thread Repair, Left Side 0.4 Hrs. 05-80-20-94 Brake Caliper Mounting Support Thread Repair, Right Side 0.4 Hrs. 05-80-20-50 Brake Caliper Mounting Support Thread Repair, Each Additional Same Side 0.1 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 4860 Front Steering Knuckle: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper, rotor, shield and ABS wheel speed sensor if equipped. 4. Remove front driveshaft. Tie Rod End 5. Remove tie rod end cotter pin and nut. Separate the tie rod from the knuckle with Remover MB-991113. 6. Support the lower suspension arm with a hydraulic jack and raise the jack to unload the rebound bumper. Upper Ball Joint 7. Remove the upper ball joint cotter pin and nut. Separate the ball joint from the knuckle with Remover MB-991113. CAUTION: When installing Remover MB-991113 to separate the ball joint, be careful not to damage the ball joint seal. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 4861 Lower Ball Joint 8. Remove the lower ball joint cotter pin and nut. Separate the ball joint from the knuckle with Remover C-4150A and remove the knuckle. 9. Remove the hub/bearing from the steering knuckle. INSTALLATION 1. Install the hub/bearing to the steering knuckle and tighten the bolts to 166 Nm (123 ft. lbs.). NOTE: When installing hub/bearing with ABS brakes, position the speed sensor opening towards the front of the vehicle. 2. Install the knuckle onto the upper and lower ball joint. CAUTION: The ball joint stud tapers must be CLEAN and DRY before installing the knuckle. Clean the stud tapers with mineral spirits to remove dirt and grease. 3. Install the upper and lower ball joint nuts. Tighten the upper ball joint nut to 81 Nm (60 ft. lbs.) and the lower ball joint nut to 183 Nm (135 ft. lbs.) then install cotter pins. Grease the lower ball joint. 4. Remove the hydraulic jack from the lower suspension arm. 5. Install the tie rod end and tighten the nut to 88 Nm (65 ft. lbs.). Install the cotter pin. 6. Install the front driveshaft. 7. Install the ABS wheel speed sensor if equipped and brake shield, rotor and caliper. 8. Install the wheel and tire assembly. 9. Remove support and lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications Stabilizer Link: Specifications REAR: Link Upper Nut ..................................................................................................................................... ................................................ 95 Nm (70 ft. lbs.) Link Lower Nut ...................................................... .............................................................................................................................. 68 Nm (50 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise Suspension Spring ( Coil / Leaf ): Customer Interest Rear Leaf Springs - Squeaking/Clicking Noise BULLETIN NUMBER: 02-05-00 GROUP: Suspension DATE: Mar.17, 2000 SUBJECT: Squeaking/**Clicking** Noise From Rear Leaf Springs MODELS: 1997 - 2000 (AN) Dakota 1998 - 2000 (DN) Durango THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-15-99, DATED NOV. 5, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED SUBJECT, PART NUMBERS, AND DIAGNOSIS. OVERVIEW: This bulletin involves replacing the spring tip liners and installing spring clinch clips and isolators. SYMPTOM/CONDITION: Squeaking/**Clicking** noise coming from the rear of the vehicle. DIAGNOSIS: **If the customer indicates that the vehicle has a squeaking/clicking noise coming from the rear of the vehicle, verify that the noise is coming from the rear springs as the vehicle's suspension goes through jounce and rebound. If a squeaking/clicking noise is coming from the rear springs, perform the Repair Procedure.** **NOTE: PERFORM THE REPAIR PROCEDURE ON ANY VEHICLE THAT HAS MISSING TIP LINERS OR MISSING CLINCH CLIP ISOLATORS AND A SQUEAKING/CLICKING NOISE IS COMING FROM THE REAR SPRINGS. PARTS REQUIRED: EQUIPMENT REQUIRED: (2) Large C-Clamps (5 - 6 in.) Large Pry Bar REPAIR PROCEDURE: DAKOTA 1. Raise the vehicle on an appropriate frame support style lift (rear axle must be allowed to extend fully) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 4874 Figure 1 2. Use an appropriate pry bar to bend open the rear spring clinch clip (Figure 1). Figure 2 3. Use the pry bar to spread apart the leaf (Figure 2). The clearance between the leaves should be enough to remove the old spring tip liner (if necessary) and install the new replacement spring tip liner. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 4875 Figure 3 4. Remove the old spring tip liner by using a hammer to drive the spring tip liner from the leaf spring (Figure 3). 5. With the prybar still inserted between the leaves, install a new spring tip liner, pin 05017561AA, onto the leaf. 6. Firmly seat the spring tip liner onto the leaf. NOTE: THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINTING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING. 7 **Apply a small amount of lubricant pin 05018626AA to the tip liner wear Pad.** 8. Perform steps 3 through 7 to the other spring tip liner Figure 4 9. Remove the clinch clip isolator from Clinch Clip and Isolator Package pin 02808399. The isolator will need to be trimmed to properly fit on Dakota models. Scribe a mark on the isolator 127 mm (5 in.) from the end of the isolator (Figure 4) then, cut the excess from the isolator. 10. Install the isolator onto the new clinch clip. 11. Position the clinch clip onto the spring in the same location as where the old clinch clip was removed. 12. Install the bottom clamp of the clinch clip. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 4876 Figure 5 13. Compress the clinch clip and the spring using a C-Clamp (Figure 5). Figure 6 14. With a hammer, bend the clinch clip tabs outboard and upward to secure the clinch clip onto the spring (Figure 6). 15. Repeat Steps 2 through 14 to remove and install all spring tip liners and clinch clips. 16. Lower the vehicle. DURANGO 1. Raise the vehicle on an appropriate frame support style lift (rear axle must be allowed to extend fully). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 4877 Figure 7 2. Use an appropriate pry bar to bend open the rear spring clinch clip (Figure 7). 3. Use the pry bar to spread apart the leaf (Figure 2). The clearance between the leaves should be enough to remove the old spring tip liner (if necessary) and install the new replacement spring tip liner. 4. Remove the old spring tip liner by using a hammer to drive the spring tip liner from the leaf spring (Figure 3). 5. With the prybar still inserted between the leaves, install a new spring tip liner, p/n **52113135AA**, onto the leaf. 6. Firmly seat the spring tip liner onto the leaf. NOTE: THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINTING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING. 7. **Apply a small of lubricant p/n 05018626AA to the tip liner wear pad.** 8. Perform steps 3 through 7 to the other two spring tip liners. 9. Install the clinch clip isolator onto the new clinch clip (see Parts Required section). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 4878 Figure 8 10. Position the new clinch clip so that the alignment tang lines up with the hole in the spring leaf (Figure 8). Figure 9 11. The clinch clip isolator and the leaf spring assembly will need to be compressed. Clamp the clinch clip and spring assembly using a C-Clamp (Figure 9). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 4879 Figure 10 Figure 11 12. Tightly clamp the side of the clinch clip to the leaf spring assembly with a second C-Clamp as shown in Figure 10 and Figure 11. Make sure that the foot of the C-Clamp does not protrude below the bottom of the leaf spring. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 4880 Figure 12 13. Remove the first C-Clamp that was installed in Step 10 (Figure 12). Figure 13 14. Using a hammer, bend the inboard clinch clip leg onto the leaf spring assembly until the locating tab is positioned into its locating hole on the leaf spring (Figure 13). 15. Next, bend the outboard clinch clip leg onto the leaf spring. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 4881 Figure 14 16. Secure the clinch clip by bending the locking tab over (Figure 14). 17. Perform Steps 1 through 16 to all clinch clips and spring tip liners. 18. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8-New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Rear Leaf Springs Squeaking/Clicking Noise BULLETIN NUMBER: 02-05-00 GROUP: Suspension DATE: Mar.17, 2000 SUBJECT: Squeaking/**Clicking** Noise From Rear Leaf Springs MODELS: 1997 - 2000 (AN) Dakota 1998 - 2000 (DN) Durango THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-15-99, DATED NOV. 5, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED SUBJECT, PART NUMBERS, AND DIAGNOSIS. OVERVIEW: This bulletin involves replacing the spring tip liners and installing spring clinch clips and isolators. SYMPTOM/CONDITION: Squeaking/**Clicking** noise coming from the rear of the vehicle. DIAGNOSIS: **If the customer indicates that the vehicle has a squeaking/clicking noise coming from the rear of the vehicle, verify that the noise is coming from the rear springs as the vehicle's suspension goes through jounce and rebound. If a squeaking/clicking noise is coming from the rear springs, perform the Repair Procedure.** **NOTE: PERFORM THE REPAIR PROCEDURE ON ANY VEHICLE THAT HAS MISSING TIP LINERS OR MISSING CLINCH CLIP ISOLATORS AND A SQUEAKING/CLICKING NOISE IS COMING FROM THE REAR SPRINGS. PARTS REQUIRED: EQUIPMENT REQUIRED: (2) Large C-Clamps (5 - 6 in.) Large Pry Bar REPAIR PROCEDURE: DAKOTA 1. Raise the vehicle on an appropriate frame support style lift (rear axle must be allowed to extend fully) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 4887 Figure 1 2. Use an appropriate pry bar to bend open the rear spring clinch clip (Figure 1). Figure 2 3. Use the pry bar to spread apart the leaf (Figure 2). The clearance between the leaves should be enough to remove the old spring tip liner (if necessary) and install the new replacement spring tip liner. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 4888 Figure 3 4. Remove the old spring tip liner by using a hammer to drive the spring tip liner from the leaf spring (Figure 3). 5. With the prybar still inserted between the leaves, install a new spring tip liner, pin 05017561AA, onto the leaf. 6. Firmly seat the spring tip liner onto the leaf. NOTE: THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINTING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING. 7 **Apply a small amount of lubricant pin 05018626AA to the tip liner wear Pad.** 8. Perform steps 3 through 7 to the other spring tip liner Figure 4 9. Remove the clinch clip isolator from Clinch Clip and Isolator Package pin 02808399. The isolator will need to be trimmed to properly fit on Dakota models. Scribe a mark on the isolator 127 mm (5 in.) from the end of the isolator (Figure 4) then, cut the excess from the isolator. 10. Install the isolator onto the new clinch clip. 11. Position the clinch clip onto the spring in the same location as where the old clinch clip was removed. 12. Install the bottom clamp of the clinch clip. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 4889 Figure 5 13. Compress the clinch clip and the spring using a C-Clamp (Figure 5). Figure 6 14. With a hammer, bend the clinch clip tabs outboard and upward to secure the clinch clip onto the spring (Figure 6). 15. Repeat Steps 2 through 14 to remove and install all spring tip liners and clinch clips. 16. Lower the vehicle. DURANGO 1. Raise the vehicle on an appropriate frame support style lift (rear axle must be allowed to extend fully). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 4890 Figure 7 2. Use an appropriate pry bar to bend open the rear spring clinch clip (Figure 7). 3. Use the pry bar to spread apart the leaf (Figure 2). The clearance between the leaves should be enough to remove the old spring tip liner (if necessary) and install the new replacement spring tip liner. 4. Remove the old spring tip liner by using a hammer to drive the spring tip liner from the leaf spring (Figure 3). 5. With the prybar still inserted between the leaves, install a new spring tip liner, p/n **52113135AA**, onto the leaf. 6. Firmly seat the spring tip liner onto the leaf. NOTE: THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINTING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING. 7. **Apply a small of lubricant p/n 05018626AA to the tip liner wear pad.** 8. Perform steps 3 through 7 to the other two spring tip liners. 9. Install the clinch clip isolator onto the new clinch clip (see Parts Required section). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 4891 Figure 8 10. Position the new clinch clip so that the alignment tang lines up with the hole in the spring leaf (Figure 8). Figure 9 11. The clinch clip isolator and the leaf spring assembly will need to be compressed. Clamp the clinch clip and spring assembly using a C-Clamp (Figure 9). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 4892 Figure 10 Figure 11 12. Tightly clamp the side of the clinch clip to the leaf spring assembly with a second C-Clamp as shown in Figure 10 and Figure 11. Make sure that the foot of the C-Clamp does not protrude below the bottom of the leaf spring. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 4893 Figure 12 13. Remove the first C-Clamp that was installed in Step 10 (Figure 12). Figure 13 14. Using a hammer, bend the inboard clinch clip leg onto the leaf spring assembly until the locating tab is positioned into its locating hole on the leaf spring (Figure 13). 15. Next, bend the outboard clinch clip leg onto the leaf spring. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 4894 Figure 14 16. Secure the clinch clip by bending the locking tab over (Figure 14). 17. Perform Steps 1 through 16 to all clinch clips and spring tip liners. 18. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8-New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Page 4895 Suspension Spring ( Coil / Leaf ): Specifications U-Bolt Nuts .......................................................................................................................................... .................................................. 122 Nm (90 ft. lbs.) Spring Eye Nut .................................................. ..................................................................................................................................... 115 Nm (85 ft. lbs.) Spring Shackle Nuts .................................................................................................................... ........................................................... 115 Nm (85 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Bushing Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring Bushing DISASSEMBLE 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. ASSEMBLE 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Bushing > Page 4898 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Leaf Spring Replace CAUTION: The rear of the vehicle must be lifted only with a jack or hoist. The lift must be placed under the frame rail crossmember located aft of the rear axle. Use care to avoid bending the side rail flange. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications Suspension Strut / Shock Absorber: Specifications FRONT: Upper Nut ............................................................................................................................................ ................................................. 26 Nm (19 ft. lbs.) Lower Bolt ............................................................ .............................................................................................................................. 108 Nm (80 ft. lbs.) REAR: Lower Nut ............................................................................................................................................ ................................................. 95 Nm (70 ft. lbs.) Upper Nut ............................................................. ................................................................................................................................ 95 Nm (70 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 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 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front > Page 4904 Suspension Strut / Shock Absorber: Testing and Inspection Rear 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. Spring And Shock Absorber Diagnosis SPRING AND SHOCK ABSORBER DIAGNOSIS Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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. Raise and support vehicle. 2. Remove the upper shock absorber nut, retainer and grommet. 3. Remove the lower bolt and remove the shock absorber. INSTALLATION NOTE: Upper shock nut must be replaced or use Mopar Lock 'N Seal or Loctite(R) 242 on existing nut. 1. Install the lower retainer (lower retainer is stamped with a L) and grommet on the shock absorber stud. Insert the shock absorber through the frame bracket hole. 2. Install the lower bolt and tighten the bolt to 108 Nm (80 ft. lbs.). 3. Install the upper grommet, retainer (upper retainer is stamped with a U) and new nut or use Mopar Lock 'N Seal or Loctite(R) 242 on existing nut, on the shock absorber stud. Tighten nut to 26 Nm (19 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4907 Suspension Strut / Shock Absorber: Service and Repair Rear REMOVAL 1. Raise vehicle and support rear axle. Shock Absorber 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 absorber. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications Suspension Travel Bumper: Specifications Bolts ..................................................................................................................................................... .................................................... 61 Nm (45 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair Torsion Bar: Service and Repair CAUTION: The left and right side torsion bars are NOT interchangeable. The bars are identified and stamped R or L, for right or left. The bars do not have a front or rear end and can be installed with either end facing forward. REMOVAL 1. Raise and support the vehicle with the front suspension hanging. 2. Turn the adjustment bolt counterclockwise to release spring load. NOTE: Count and record the number of turns for installation reference. 3. Remove the adjustment bolt from swivel. 4. Remove torsion bar and anchor. Remove anchor from torsion bar. 5. Remove all foreign material from torsion bar mounting in anchor and suspension arm. 6. Inspect adjustment bolt, bearing and swivel for damage. INSTALLATION 1. Insert torsion bar ends into anchor and suspension arm. 2. Position anchor and bearing in frame crossmember. Install adjustment bolt through bearing, anchor and into the swivel. 3. Turn adjustment bolt clockwise the recorded amount of turns. 4. Lower vehicle and adjust the front suspension height. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Front Hub Seals - Grease Purge Explanation Wheel Bearing: Technical Service Bulletins Front Hub Seals - Grease Purge Explanation NUMBER: 02-06-99 Rev. A GROUP: Suspension DATE: Dec. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-06-99, DATED JUNE 11, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF 4X2 MODELS AND ADDITIONAL MODEL YEARS. SUBJECT: Front Wheel Bearing Grease Is Evident On The Bearing Seal Area. MODELS: 1997 - **2000** (AN) Dakota 1994 - **2000** (BR/BE) Ram Truck 1998 - **2000** (DN) Durango DISCUSSION: Front wheel bearings may be incorrectly diagnosed as faulty due to the evidence of wheel bearing grease on the bearing seal areas. This grease purge is a normal design condition. The factory fill of the bearings includes a slightly greater amount of grease than is required for the bearing lifetime lubricant. A portion of the grease purges through the self-venting seal in the initial few thousand miles to form an additional barrier in the area of the seal and the stamped slinger. This barrier aids in the prevention of contaminants passing through the seal and into the bearing. Do not remove or clean the purged grease as part of normal maintenance due to the fact that it provides additional protection and once removed, damage to the seal and bearing could result. NOTE: UNDER NORMAL CONDITIONS, THERE MAY BE A SPLATTERING OF GREASE RADIALLY OUTWARD ON THE STEERING KNUCKLE FROM THE GREASE BARRIER AREA THAT CAN BE AS THICK AS 4 MM (0.125 IN.). Front wheel bearings should be replaced only if: ^ The seal shows visible damage ^ The bearing endplay is greater than 0.13 mm (0.005 in.) ^ The bearing was operated without the proper clamping force from the spindle nut ^ The bearing has a rough, sticky feel when rotated POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Page 4918 Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Page 4919 Wheel Bearing: Service Precautions Use only a grease that is recommended for wheel bearing applications. Use of the improper grease can cause bearing damage. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Refer to Axle Shaft, Conventional Fixed/Floating, Axle Shaft Seal for procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4922 Wheel Bearing: Service and Repair Rear Refer to Axle Shaft, Conventional Fixed/Floating, Axle Shaft Seal for procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Nut, Axle 180 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity and reinstall. Do not exceed speeds of 50 MPH. Refer to Owner's Manual for complete details. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation Wheels: Description and Operation 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 4935 Wheels: Testing and 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 4936 Wheels: Service and Repair The wheel studs and nuts are designed for specific applications. They must be replaced with equivalent parts. Do not use replacement parts of lesser quality or a substitute design. All aluminum and some steel wheels have wheel stud nuts which feature an enlarged nose. This enlarged nose is necessary to ensure proper retention of the aluminum wheels. NOTE: Do not use chrome plated lug nuts with chrome plated wheels. Before installing the wheel, be sure to remove any build up of corrosion on the wheel mounting surfaces. Ensure wheels are installed with good metal-to-metal contact. Improper installation could cause loosening of wheel nuts. This could affect the safety and handling of your vehicle. To install the wheel, first position it properly on the mounting surface. All wheel nuts should then be tightened just snug. Gradually tighten them in sequence to the proper torque specification. Never use oil or grease on studs or nuts. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Front Hub Seals - Grease Purge Explanation Wheel Bearing: Technical Service Bulletins Front Hub Seals - Grease Purge Explanation NUMBER: 02-06-99 Rev. A GROUP: Suspension DATE: Dec. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-06-99, DATED JUNE 11, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF 4X2 MODELS AND ADDITIONAL MODEL YEARS. SUBJECT: Front Wheel Bearing Grease Is Evident On The Bearing Seal Area. MODELS: 1997 - **2000** (AN) Dakota 1994 - **2000** (BR/BE) Ram Truck 1998 - **2000** (DN) Durango DISCUSSION: Front wheel bearings may be incorrectly diagnosed as faulty due to the evidence of wheel bearing grease on the bearing seal areas. This grease purge is a normal design condition. The factory fill of the bearings includes a slightly greater amount of grease than is required for the bearing lifetime lubricant. A portion of the grease purges through the self-venting seal in the initial few thousand miles to form an additional barrier in the area of the seal and the stamped slinger. This barrier aids in the prevention of contaminants passing through the seal and into the bearing. Do not remove or clean the purged grease as part of normal maintenance due to the fact that it provides additional protection and once removed, damage to the seal and bearing could result. NOTE: UNDER NORMAL CONDITIONS, THERE MAY BE A SPLATTERING OF GREASE RADIALLY OUTWARD ON THE STEERING KNUCKLE FROM THE GREASE BARRIER AREA THAT CAN BE AS THICK AS 4 MM (0.125 IN.). Front wheel bearings should be replaced only if: ^ The seal shows visible damage ^ The bearing endplay is greater than 0.13 mm (0.005 in.) ^ The bearing was operated without the proper clamping force from the spindle nut ^ The bearing has a rough, sticky feel when rotated POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 4941 Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 4942 Wheel Bearing: Service Precautions Use only a grease that is recommended for wheel bearing applications. Use of the improper grease can cause bearing damage. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Refer to Axle Shaft, Conventional Fixed/Floating, Axle Shaft Seal for procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4945 Wheel Bearing: Service and Repair Rear Refer to Axle Shaft, Conventional Fixed/Floating, Axle Shaft Seal for procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Nut, Axle 180 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence Wheel Fastener: Specifications Wheel Tightening Sequence Wheel Torque Sequence - Master Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 4954 Wheel Fastener: Specifications Lug Nut Torque Lug Nut ................................................................................................................................................ ................................ 115 - 157 Nm (85 - 115 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 4955 Wheel Fastener: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper and rotor. Fig. 9 4. Remove stud from hub with Remover C-4150A. INSTALLATION 1. Install new stud into hub flange. 2. Install three washers onto stud, then install lug nut with the flat side of the nut against the washers. 3. Tighten lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange. 4. Remove lug nut and washers. 5. Install the brake rotor and caliper. 6. Install wheel and tire assembly, use new lug nut on stud or studs that were replaced. 7. Remove support and lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Specifications Air Door Actuator / Motor: Specifications Floor-Defrost Door Actuator Mounting Screws 20 in.lb Panel-Defrost Door Actuator Mounting Screws 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Specifications > Page 4961 Air Door Actuator / Motor: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Floor Door Actuator Replacement Air Door Actuator / Motor: Service and Repair Floor Door Actuator Replacement WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, 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 vehicle. Refer to: ""Body and Frame : Interior Trim : Dashboard/Instrument Panel : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair Floor-Defrost Door Actuator Remove/Install 3. Unplug the two vacuum harness connectors from the floor-defrost door actuator. 4. Remove the push nut retainer that secures the floor-defrost door actuator link to the floor-defrost door crank arm. 5. Remove the two screws that secure the floor defrost door actuator to the heater-A/C housing. 6. Disengage the floor-defrost door actuator link from the floor-defrost door crank arm and remove the actuator from the heater-A/C housing. 7. Reverse the removal procedures to install. Tighten the floor-defrost door actuator mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Floor Door Actuator Replacement > Page 4964 Air Door Actuator / Motor: Service and Repair Panel/Defrost Door Actuator Replacement WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, 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 vehicle. Refer to: "Body and Frame : Interior Trim : Dashboard/Instrument Panel : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair Panel-Defrost Door Actuator 3. Unplug the vacuum harness connector from the panel-defrost door actuator. 4. Remove the two screws that secure the panel-defrost door actuator to the heater-A/C housing. 5. Rotate the panel-defrost door actuator clockwise about one-quarter turn to disengage the hooked end of the actuator link from the hole on the end of the panel-defrost door lever. 6. Remove the panel-defrost door actuator from the heater-A/C housing. 7. Reverse the removal procedures to install. Tighten panel-defrost door actuator mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Floor Door Actuator Replacement > Page 4965 Air Door Actuator / Motor: Service and Repair Recirculation Air Door Actuator Replacement WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. A recirculation air door and vacuum actuator are used only on models with the optional air conditioning system. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the vehicle. Refer to: "Body and Frame : Interior Trim : Dashboard/Instrument Panel : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 3. If the vehicle is so equipped, and the heater-A/C housing is in its installed position in the vehicle, remove the Infinity speaker system amplifier. Recirculation Air Door Actuator Remove/Install 4. Unplug the two vacuum harness connectors from the recirculation air door actuator. 5. Remove the two stamped nuts that secure the recirculation air door actuator to the blower motor housing cover. 6. Unhook the actuator link from the recirculation air door lever. 7. Remove the actuator from the blower motor housing cover. 8. Reverse the removal procedures to install. Tighten the mounting nuts until the recirculation air door actuator is seated to the blower motor housing cover. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Cable: > 24-11-99 > Jun > 99 > A/C System Cooling Performance Deterioration Air Door Cable: Customer Interest A/C System - Cooling Performance Deterioration NUMBER: 24-11-99 GROUP: Heating & A/C DATE: June 25, 1999 SUBJECT: A/C Cooling Performance Deteriorates After A Few Minutes Of Operation OVERVIEW: This bulletin involves adjusting the temperature control cable or installing a new A/C Evaporator MODELS: 1998 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AIR CONDITIONING. SYMPTOM/CONDITION: A/C cooling performance deteriorates after a few minutes of operation. DIAGNOSIS: WARNING: EYE PROTECTION MUST BE WORN WHEN SERVICING THE AIR CONDITIONING REFRIGERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE) ALL VALVES ON THE EQUIPMENT BEING USED BEFORE CONNECTING TO OR DISCONNECTING FROM THE REFRIGERANT SYSTEM. FAILURE TO OBSERVE THESE WARNINGS MAY RESULT IN PERSONAL INJURY. NOTE: THE AIR TEMPERATURE IN THE TEST ROOM AND IN THE VEHICLE MUST BE A MINIMUM OF 21° C. (70° F.) FOR THIS TEST. 1. Connect a tachometer and a manifold gauge set to the vehicle. 2. Set the heater-NC mode control switch knob in the recirculation mode (Max-A/C) position, the temperature control knob in the full cool position, and the blower motor switch knob in the highest speed position. On Durango models with rear NC, set the rear A/C blower control knob to the OFF position. 3. Start the engine and hold the idle at 1000 rpm with the compressor clutch engaged. Refer to the appropriate Service Manual, Group 24, Diagnosis and Testing section if the compressor clutch does not engage. 4. During the test, the engine should be at operating temperature, the doors and windows closed, and the hood mostly closed. 5. Insert a thermometer into the driver side center A/C (panel) outlet. 6. With the compressor clutch engaged, record the panel outlet temperature every 30 seconds for at least five minutes. The temperature should drop at least 20° F. below the ambient temperature within the first 60 seconds of operation. The temperature should continue to drop. After five minutes, the outlet temperature must be at or below those listed in the Performance Temperature and Pressure Chart identified in Group 24 of the appropriate Service Manual. 7. If the suction pressure meets the requirements listed in the Performance Temperature and Pressure Chart identified in Group 24 of the appropriate Service Manual, record the outlet temperature reading. Clamp off both heater hoses (inlet and outlet). Wait five minutes and record the temperature again. Compare the second reading to the list in the Performance Temperature and Pressure Chart. If the temperature is now within the appropriate ranges, the temperature control cable must be adjusted. Refer to the appropriate Service Manual, Group 24, Adjustment section. 8. If the panel outlet temperature began to rise after two - three minutes of operation and eventually levels off at ambient temperature or, the suction pressure drops to 13 psig or less, or the clutch disengages and begins to cycle, perform the Repair Procedure. PARTS REQUIRED: AR (1) 05015440AA Coil, Evaporative, Durango Models Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Cable: > 24-11-99 > Jun > 99 > A/C System Cooling Performance Deterioration > Page 4974 AR (1) 04885579AA Coil, Evaporative, Dakota Models AR 82300101 Refrigerant, R134 EQUIPMENT REQUIRED: R134a Refrigerant/Recycling/Charging Station REPAIR PROCEDURE: 1. Replace the evaporative coil. Refer to the appropriate Service Manual, Group 24, Removal and Installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-50-25-93 Adjust The Temperature Control Cable 1.5 Hrs. 24-65-02-98 Replace The Evaporator Coil 3.8 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Cable: > 24-11-99 > Jun > 99 > A/C System - Cooling Performance Deterioration Air Door Cable: All Technical Service Bulletins A/C System - Cooling Performance Deterioration NUMBER: 24-11-99 GROUP: Heating & A/C DATE: June 25, 1999 SUBJECT: A/C Cooling Performance Deteriorates After A Few Minutes Of Operation OVERVIEW: This bulletin involves adjusting the temperature control cable or installing a new A/C Evaporator MODELS: 1998 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AIR CONDITIONING. SYMPTOM/CONDITION: A/C cooling performance deteriorates after a few minutes of operation. DIAGNOSIS: WARNING: EYE PROTECTION MUST BE WORN WHEN SERVICING THE AIR CONDITIONING REFRIGERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE) ALL VALVES ON THE EQUIPMENT BEING USED BEFORE CONNECTING TO OR DISCONNECTING FROM THE REFRIGERANT SYSTEM. FAILURE TO OBSERVE THESE WARNINGS MAY RESULT IN PERSONAL INJURY. NOTE: THE AIR TEMPERATURE IN THE TEST ROOM AND IN THE VEHICLE MUST BE A MINIMUM OF 21° C. (70° F.) FOR THIS TEST. 1. Connect a tachometer and a manifold gauge set to the vehicle. 2. Set the heater-NC mode control switch knob in the recirculation mode (Max-A/C) position, the temperature control knob in the full cool position, and the blower motor switch knob in the highest speed position. On Durango models with rear NC, set the rear A/C blower control knob to the OFF position. 3. Start the engine and hold the idle at 1000 rpm with the compressor clutch engaged. Refer to the appropriate Service Manual, Group 24, Diagnosis and Testing section if the compressor clutch does not engage. 4. During the test, the engine should be at operating temperature, the doors and windows closed, and the hood mostly closed. 5. Insert a thermometer into the driver side center A/C (panel) outlet. 6. With the compressor clutch engaged, record the panel outlet temperature every 30 seconds for at least five minutes. The temperature should drop at least 20° F. below the ambient temperature within the first 60 seconds of operation. The temperature should continue to drop. After five minutes, the outlet temperature must be at or below those listed in the Performance Temperature and Pressure Chart identified in Group 24 of the appropriate Service Manual. 7. If the suction pressure meets the requirements listed in the Performance Temperature and Pressure Chart identified in Group 24 of the appropriate Service Manual, record the outlet temperature reading. Clamp off both heater hoses (inlet and outlet). Wait five minutes and record the temperature again. Compare the second reading to the list in the Performance Temperature and Pressure Chart. If the temperature is now within the appropriate ranges, the temperature control cable must be adjusted. Refer to the appropriate Service Manual, Group 24, Adjustment section. 8. If the panel outlet temperature began to rise after two - three minutes of operation and eventually levels off at ambient temperature or, the suction pressure drops to 13 psig or less, or the clutch disengages and begins to cycle, perform the Repair Procedure. PARTS REQUIRED: AR (1) 05015440AA Coil, Evaporative, Durango Models Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Cable: > 24-11-99 > Jun > 99 > A/C System - Cooling Performance Deterioration > Page 4980 AR (1) 04885579AA Coil, Evaporative, Dakota Models AR 82300101 Refrigerant, R134 EQUIPMENT REQUIRED: R134a Refrigerant/Recycling/Charging Station REPAIR PROCEDURE: 1. Replace the evaporative coil. Refer to the appropriate Service Manual, Group 24, Removal and Installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-50-25-93 Adjust The Temperature Control Cable 1.5 Hrs. 24-65-02-98 Replace The Evaporator Coil 3.8 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Technical Service Bulletins > Page 4981 Temperature Control Cable Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Technical Service Bulletins > Page 4982 Air Door Cable: Adjustments Any time the heater-A/C control or the temperature control cable are removed and/or replaced, the following procedure must be performed. 1. The temperature control cable housing and core must be installed at both the heater-A/C control and the heater-A/C housing ends, and the heater-A/C control must be installed in the instrument panel. 2. Rotate the temperature control knob on the heater-A/C control so that the knob pointer is in the 12 o' clock position. 3. Pull the temperature control knob straight out from the heater-A/C control base until the perimeter of the knob (not the knob pointer) protrudes about 6 millimeters (0.25 inch) from the face of the control base. 4. Rotate the temperature control knob to the 1 o'clock position. Push in on the knob slightly and continue rotating the knob to its full clockwise stop. The knob pointer should be aimed at a position about 8 millimeters (0.315 inch) beyond the end of the graduated red strobe temperature control graphic on the face of the heater-A/C control base. If the knob is not pointed to the correct position, go back to Step 2 and repeat the adjustment procedure. 5. Rotate the temperature control knob counterclockwise until the knob pointer is in the 12 o'clock position again. 6. Push the temperature control knob straight in towards the heater-A/C control base until the perimeter of the knob (not the knob pointer) is flush with the face of the heater-A/C control base. 7. Rotate the knob to its full clockwise stop again. The knob pointer should be aimed at the end of the graduated red strobe temperature control graphic on the face of the heater-A/C control base. If OK, go to Step 8. If not OK, go back to Step 2. 8. Rotate the knob to its full counterclockwise stop and release the knob. If the knob springs back from the counterclockwise stop, the self-adjuster clip that secures the temperature control cable to the blend-air door lever is improperly installed. If the knob does not spring back, the temperature control cable adjustment is complete. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Technical Service Bulletins > Page 4983 Air Door Cable: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Roll down the instrument panel assembly, but do not remove it from the vehicle. Refer to: "Body and Frame : Interior Trim : Dashboard/Instrument Panel : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 3. Disconnect the temperature control cable from the heater-A/C control. Temperature Control Cable Remove/Install 4. Disconnect the temperature control cable housing flag retainer from the receptacle on the top of the heater-A/C housing. 5. Pull the temperature control cable core self-adjuster clip off of the pin on the end of the blend-air door lever. 6. Remove the temperature control cable from the vehicle. INSTALLATION Temperature Control Cable Self-Adjuster Clip Before installing the temperature control cable, be certain that the self-adjuster clip is properly positioned. This measurement must be made with the cable end bottomed against the flag retainer on the heater-A/C control end of the cable housing. The measurement is taken from the end of the flag retainer on the heater-A/C housing end of the cable to the center of the self-adjuster clip. If the self-adjuster clip is not properly positioned, slide the clip up or down the cable core as required to achieve the specified dimension. 1. Connect the temperature control cable to the heater-A/C control. 2. Route the cable through the instrument panel. Position the cable end near the connection points on the HVAC unit assembly, making sure not to kink or distort the cable. 3. Push the temperature control cable core self-adjuster clip onto the pin on the end of the blend-air door lever. 4. Snap the temperature control cable housing flag retainer into the receiver on the top of the heater-A/C housing. 5. Reinstall the instrument panel assembly. Refer to: "Body and Frame : Interior Trim : Dashboard/Instrument Panel : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 6. Connect the battery negative cable. 7. Adjust the temperature control cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications Air Duct: Specifications Front Seat Floor Duct Mounting Screws 20 in.lb Demister Duct Adapter Mounting Screws 20 in.lb Hose Mounting Screw h in.lb Demister Ducts And Outlets Mounting Screws 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications > Page 4987 Air Duct: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIR BAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications > Page 4988 Air Duct: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. Panel And Defroster Ducts The panel and defroster ducts are integral to the instrument panel assembly. The defroster outlets are integral to the instrument panel top cover. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Procedures/Instrument Panel Assembly Replacement Outlet Barrels In addition to the panel outlet barrels in the instrument panel, models equipped with the bucket seat option have two outlet barrels for the rear seat passengers located near the top of upper rear panel of the center floor console. The service procedures for all of these outlet barrels is the same. Models with the optional rear overhead A/C unit also have four outlet barrels located in the outlet bezel on the headliner, but these outlet barrels are only serviced as a unit with the rear overhead A/C outlet bezel. Outlet Barrels 1. Using a trim stick or another suitable widebladed flat tool, gently pry at the sides of the outlet barrels to release the snap-fit pivots on the barrel from the pivot pins in the outlet housing of the instrument panel top cover, the instrument cluster bezel or the center floor console. 2. To install the outlet barrel, position the barrel in the outlet housing and press inwards firmly and evenly until the barrel snaps into place. Front Seat Floor Duct Front Seat Floor Duct Remove/Install - Typical 1. Remove the three screws that secure the floor duct to the bottom of the heater-A/C housing. 2. Remove the floor duct from the heater-A/C housing. 3. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Rear Seat Floor Duct Control Split Bench Seat Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications > Page 4989 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 section. 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. 3. Reverse the removal procedures to install. Bucket Seat The rear floor duct control and linkage are only serviced as a unit with the console duct assembly. 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. 4. Reverse the removal procedures to install. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications > Page 4990 Rear Seat Floor Duct The rear seat floor duct damper door is only serviced 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. Rear Seat Floor Duct Remove/Install - Split Bench Seat Rear Seat Floor Duct Remove/Install - Bucket 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. 4. Reverse the removal procedures to install. Demister Duct Adapter 1. Roll the instrument panel assembly down, but do not remove it from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Procedures/Instrument Panel Assembly Replacement 2. Disconnect the flexible demister duct hose from the demister duct adapter on the top of the heater- A/C housing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications > Page 4991 Demister Duct Adapter Remove/Install 3. Remove the two screws that secure the demister duct adapter to the top of the heater-A/C housing. 4. Remove the demister duct adapter from the heater-A/C housing. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Demister Hose 1. Remove the heater-A/C control from the instrument panel. 2. Reach through the heater-A/C control opening in the instrument panel to access and remove the screw that secures the flexible demister duct hose to the demister duct tee. 3. Roll the instrument panel assembly down, but do not remove it from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Procedures/Instrument Panel Assembly Replacement 4. Disconnect the flexible demister duct hose from the demister duct adapter on the top of the heater- A/C housing. 5. Remove the demister duct hose from the demister duct tee near the underside of the instrument panel top cover. 6. Reverse the removal procedures to install. Tighten the hose mounting screw to 2.2 Nm (20 in. lbs.). Demister Ducts And Outlets 1. Remove the instrument panel top cover from the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Procedures/Instrument Panel Assembly Replacement Demister Ducts Remove/Install 2. Remove the screws (two - left side, three - right side) that secure the demister ducts to the instrument panel top cover. 3. Using a trim stick or another suitable wide flat-bladed tool, gently pry between the end of the demister duct and the demister outlet flange to release the duct from the outlet. 4. Remove the demister ducts and the tee from the instrument panel top cover. 5. Squeeze the demister outlet flange from the underside of the instrument panel top cover and push it out through the top. 6. Using a trim stick or another suitable wide flat-bladed tool, gently pry between the end of the demister duct and the demister outlet flange to release the duct from the outlet. 7. Remove the demister ducts and the tee from the instrument panel top cover. 8. Squeeze the demister outlet flange from the underside of the instrument panel top cover and push it out through the top. 9. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications > Page 4992 Heater-A/C Housing Plenum Adapter 1. Remove the heater-A/C housing from the vehicle. Heater-A/C Housing Plenum Adapter Remove/Install 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. 6. Reverse the remaining removal procedures to complete the installation. Rear Overhead A/C Outlet Bezel The rear overhead A/C outlet bezel is used only on models with the optional rear overhead A/C unit. The outlet barrels located in the bezel are only serviced as a unit with the rear overhead A/C outlet bezel. Rear Overhead A/C Outlet Bezel Remove/Install 1. Using a trim stick or another suitable wide flat-bladed tool, gently pry between both ends of the rear overhead A/C outlet bezel and the headliner to release the two snap clip retainers that secure the bezel to the rear overhead A/C unit housing. 2. Remove the rear overhead A/C outlet bezel from the headliner mounting hole. 3. Reverse the removal procedures to install. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair Air Register: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. Panel And Defroster Ducts The panel and defroster ducts are integral to the instrument panel assembly. The defroster outlets are integral to the instrument panel top cover. Refer to: "Body and Frame : Interior Trim : Dashboard/Instrument Panel : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair Outlet Barrels In addition to the panel outlet barrels in the instrument panel, models equipped with the bucket seat option have two outlet barrels for the rear seat passengers located near the top of upper rear panel of the center floor console. The service procedures for all of these outlet barrels is the same. Models with the optional rear overhead A/C unit also have four outlet barrels located in the outlet bezel on the headliner, but these outlet barrels are only serviced as a unit with the rear overhead A/C outlet bezel. Outlet Barrels 1. Using a trim stick or another suitable widebladed flat tool, gently pry at the sides of the outlet barrels to release the snap-fit pivots on the barrel from the pivot pins in the outlet housing of the instrument panel top cover, the instrument cluster bezel or the center floor console. 2. To install the outlet barrel, position the barrel in the outlet housing and press inwards firmly and evenly until the barrel snaps into place. Front Seat Floor Duct Front Seat Floor Duct Remove/Install - Typical 1. Remove the three screws that secure the floor duct to the bottom of the heater-A/C housing. 2. Remove the floor duct from the heater-A/C housing. 3. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Rear Seat Floor Duct Control Split Bench Seat Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Page 4996 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 section. 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. 3. Reverse the removal procedures to install. Bucket Seat The rear floor duct control and linkage are only serviced as a unit with the console duct assembly. 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. 4. Reverse the removal procedures to install. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Page 4997 Rear Seat Floor Duct The rear seat floor duct damper door is only serviced 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. Rear Seat Floor Duct Remove/Install - Split Bench Seat Rear Seat Floor Duct Remove/Install - Bucket 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. 4. Reverse the removal procedures to install. Demister Duct Adapter 1. Roll the instrument panel assembly down, but do not remove it from the vehicle. Refer to: "Body and Frame : Interior Trim : Dashboard/Instrument Panel : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 2. Disconnect the flexible demister duct hose from the demister duct adapter on the top of the heater- A/C housing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Page 4998 Demister Duct Adapter Remove/Install 3. Remove the two screws that secure the demister duct adapter to the top of the heater-A/C housing. 4. Remove the demister duct adapter from the heater-A/C housing. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Demister Hose 1. Remove the heater-A/C control from the instrument panel. 2. Reach through the heater-A/C control opening in the instrument panel to access and remove the screw that secures the flexible demister duct hose to the demister duct tee. 3. Roll the instrument panel assembly down, but do not remove it from the vehicle. Refer to: "Body and Frame : Interior Trim : Dashboard/Instrument Panel : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 4. Disconnect the flexible demister duct hose from the demister duct adapter on the top of the heater- A/C housing. 5. Remove the demister duct hose from the demister duct tee near the underside of the instrument panel top cover. 6. Reverse the removal procedures to install. Tighten the hose mounting screw to 2.2 Nm (20 in. lbs.). Demister Ducts And Outlets 1. Remove the instrument panel top cover from the instrument panel. Refer to: "Body and Frame : Interior Trim : Dashboard/Instrument Panel : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair Demister Ducts Remove/Install 2. Remove the screws (two - left side, three - right side) that secure the demister ducts to the instrument panel top cover. 3. Using a trim stick or another suitable wide flat-bladed tool, gently pry between the end of the demister duct and the demister outlet flange to release the duct from the outlet. 4. Remove the demister ducts and the tee from the instrument panel top cover. 5. Squeeze the demister outlet flange from the underside of the instrument panel top cover and push it out through the top. 6. Using a trim stick or another suitable wide flat-bladed tool, gently pry between the end of the demister duct and the demister outlet flange to release the duct from the outlet. 7. Remove the demister ducts and the tee from the instrument panel top cover. 8. Squeeze the demister outlet flange from the underside of the instrument panel top cover and push it out through the top. 9. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Heater-A/C Housing Plenum Adapter 1. Remove the heater-A/C housing from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Page 4999 Heater-A/C Housing Plenum Adapter Remove/Install 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. 6. Reverse the remaining removal procedures to complete the installation. Rear Overhead A/C Outlet Bezel The rear overhead A/C outlet bezel is used only on models with the optional rear overhead A/C unit. The outlet barrels located in the bezel are only serviced as a unit with the rear overhead A/C outlet bezel. Rear Overhead A/C Outlet Bezel Remove/Install 1. Using a trim stick or another suitable wide flat-bladed tool, gently pry between both ends of the rear overhead A/C outlet bezel and the headliner to release the two snap clip retainers that secure the bezel to the rear overhead A/C unit housing. 2. Remove the rear overhead A/C outlet bezel from the headliner mounting hole. 3. Reverse the removal procedures to install. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Ambient Temperature Sensor / Switch HVAC: Specifications Ambient Temperature Sensor Bracket to Radiator Yoke Screw 50 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 5003 Ambient Temperature Sensor / Switch HVAC: Locations Ambient Temperature Sensor Remove/Install The ambient temperature sensor is mounted on the right side of the radiator yoke behind the grille. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 5004 Ambient Air Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 5005 Ambient Temperature Sensor / Switch HVAC: Description and Operation DESCRIPTION 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. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. OPERATION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 5006 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 (231° 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. 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 kilohms. At 55° C (131° F), the sensor resistance is 2.488 kilohms. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 5007 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Specifications Blower Motor: Specifications Blower Motor/Air Spoiler/Wheel Assembly to Heater-A/C Housing Screws (3) 20 in.lb Rear Blower Motor/Wheel/Housing Unit Mounting Screws (4) 27 in.lb Lower Housing Cover to Rear Overhead A/C Unit Screws (9) 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Specifications > Page 5011 Blower Motor: Locations The blower motor and blower wheel are located in the passenger side end of the heater-A/C housing, below the glove box. The rear blower motor and blower wheel are mounted to a blower wheel housing located inside the rear overhead A/C unit, above the headliner. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Specifications > Page 5012 Blower Motor: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Specifications > Page 5013 Blower Motor: Description and Operation Hardwired to control head = resistor block SYSTEM DESCRIPTION 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 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, 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. Rear The rear blower motor and blower wheel are mounted to a blower wheel housing located inside the rear overhead A/C unit, above the headliner. The blower motor controls the velocity of air flowing through the overhead 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Specifications > Page 5014 Blower Motor: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. 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 (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 overhead 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front Blower Motor Replacement Blower Motor: Service and Repair Front Blower Motor Replacement WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO 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. REMOVAL 1. Remove and disassemble the heater-A/C housing. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Heater - A/C Housing Removal and Installation, See: Housing Assembly HVAC/Service and Repair/Heater - A/C Housing Removal and Installation Blower Motor Remove/Install 2. Remove the three screws that secure the blower motor, air spoiler, and blower wheel assembly to the heater-A/C housing. 3. 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. Blower Motor Wheel Remove/Install 4. Remove the blower wheel retainer clip and remove the wheel from the blower motor shaft. INSTALLATION 1. Press the blower wheel hub onto the blower motor shaft. Be sure the flat on the blower motor shaft is indexed to the flat on the inside of the blower wheel hub. 2. Install the retainer clip over the blower wheel hub. The ears of the retainer clip must be indexed over the flats on the blower motor shaft and blower wheel hub. 3. 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. 4. 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. 5. 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.). 6. Assemble and install the heater-A/C housing. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Heater - A/C Housing Removal and Installation, See: Housing Assembly HVAC/Service and Repair/Heater - A/C Housing Removal and Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front Blower Motor Replacement > Page 5017 Installation Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front Blower Motor Replacement > Page 5018 Blower Motor: Service and Repair Rear Blower Motor Replacement WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO 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. The rear blower motor is used only on models with the optional rear overhead 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. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the headliner from the passenger compartment of the vehicle. Rear Overhead A/C Drain Hose Remove/Install 3. Disconnect the B-pillar drain hoses from the way fittings on each side of the rear overhead A/C unit. 4. Remove the nine screws that secure the lower housing cover to the rear overhead A/C unit. Rear Overhead A/C Unit Lower Housing Cover Remove/Install 5. Release the lower housing cover snap retainer near the center of the outlet side (rear) of the rear overhead A/C unit. 6. Feed the rear blower motor switch wire harness and connector through the hole in the right end of the rear overhead A/C unit lower housing cover while removing the cover from the unit. 7. Disengage the rear blower motor wire harness connector retainer from the mounting hole in the left rear corner of the rear overhead A/C unit upper housing cover. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front Blower Motor Replacement > Page 5019 Rear Blower Motor And Wheel Remove/Install 8. Unplug the rear blower motor wire harness connector. 9. Remove the four screws that secure the rear blower motor, wheel and housing unit to the rear overhead A/C unit upper housing cover. 10. Lower the rear blower motor, wheel and housing unit far enough to access and disengage the rear overhead A/C unit wire harness from each end of the blower housing. 11. Remove the rear blower motor, wheel and housing unit from the rear overhead A/C unit. INSTALLATION 1. Position the rear blower motor, wheel and housing unit to the rear overhead A/C unit, and start the four mounting screws to hold it in position. 2. Engage the rear overhead A/C unit wire harness in the routing holes on each end of the blower housing. 3. Finish installing the four rear blower motor, wheel and housing unit mounting screws. Tighten the mounting screws to 3 Nm (27 in. lbs.). 4. Plug in the rear blower motor wire harness connector. 5. Engage the rear blower motor wire harness connector retainer in the mounting hole in the left rear corner of the rear overhead A/C unit upper housing cover. 6. Feed the rear blower motor switch wire harness and connector through the hole in the right end of the rear overhead A/C unit lower housing cover while positioning the cover to the unit. 7. Be certain that the lower housing cover snap retainer near the center of the outlet side (rear) of the rear overhead A/C unit is engaged. 8. Install the nine screws that secure the lower housing cover to the rear overhead A/C unit. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 9. Connect the B-pillar drain hoses to the way fittings on each side of the rear overhead A/C unit. 10. Reinstall the headliner to the passenger compartment of the vehicle. 11. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Component Locations Blower Motor Relay: Component Locations Power Distribution Center The blower motor relay is located in the PDC in the engine compartment. The high speed blower motor relay is located in the relay and fuse block, which is attached to the back of the junction block, under the left side of the instrument panel in the passenger compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Component Locations > Page 5024 Blower Motor Relay: Connector Locations Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Component Locations > Page 5025 Blower Motor Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 5026 Blower Motor Relay: Description and Operation SYSTEM DESCRIPTION The blower motor relay is an International Standards Organization (ISO)-type relay. The relay is an electromechanical device that switches battery current from a fuse in the Power Distribution Center (PDC) directly to the blower motor. The relay is energized when the relay coil is provided a voltage signal by the ignition switch. This arrangement reduces the amount of battery current that must flow through the ignition switch. The blower motor relay control circuit is protected by a fuse located in the junction block. When the relay is de-energized, the blower motor receives no battery current. The blower motor relay is located in the PDC in the engine compartment. Refer to the PDC label for blower motor relay identification and location. The blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. High Speed Blower Motor Relay The front blower motor electrical circuit uses a high speed blower motor relay. The high speed blower motor relay is an International Standards Organization (ISO)-type relay. The relay is an electromechanical device that switches the blower motor to ground, bypassing the remainder of the blower motor feed circuit. The high speed blower motor relay is energized when the relay coil is provided a ground signal by the blower motor switch, and a battery feed from the ignition switch. When the relay is de-energized, the front blower motor ground feed is routed through the front blower motor switch and the blower motor resistor. The high speed blower motor relay is located in the relay and fuse block, which is attached to the back of the junction block, under the left side of the instrument panel in the passenger compartment. The high speed blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 5027 Blower Motor Relay: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Relay Test Blower Motor Relay The high speed blower motor relay is located in the relay and fuse block, which is attached to the back of the junction block, under the left side of the instrument panel in the passenger compartment. Remove the high speed blower motor relay from the relay and fuse block as described 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 Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the ground side of the blower motor. There should be continuity between the ground circuit cavity of the blower motor wire harness connector and the relay and fuse block cavity for relay terminal 30 at all times. If OK, go to Step 2. If not OK, repair the open circuit to the blower motor as required. 2. The relay normally closed terminal cavity (87A) is not used for this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to ground. When the relay is energized, terminal 87 is connected to terminal 30 and provides a direct path to ground for the blower motor. There should be continuity between the relay and fuse block cavity for terminal 87 and ground at all times. If OK, go to Step 4. If not OK, repair the open circuit to ground as required. 4. The coil battery terminal cavity (86) is connected to the ignition switch. When the ignition switch is placed in the On position, fused ignition switch output is directed from a fuse in the junction block to the relay electromagnetic coil to energize the relay There should be battery voltage at the relay and fuse block 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 junction block fuse as required. 5. The coil ground terminal cavity (85) is connected to the high speed output circuit terminal of the blower motor switch. This terminal supplies the ground for the relay electromagnetic coil. There should be continuity between the relay and fuse block cavity for relay terminal 85 and the high speed output circuit terminal of the blower motor switch at all times. If not OK, repair the open circuit to the blower motor switch as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 5028 Blower Motor Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for blower motor relay identification and location. 4. Unplug the blower motor relay from the PDC. 5. Install the blower motor relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications Blower Motor Resistor: Specifications Front Blower Motor Resistor Mounting Screws 20 in.lb Rear Blower Motor Resistor Mounting Screws 20 in.lb Lower Housing Cover to Rear Overhead A/C Unit Mounting Screws (9) 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications > Page 5032 Blower Motor Resistor: Locations Blower Motor Resistor Remove/Install Blower Motor Resistor - Factory Installation The front blower motor resistor is mounted to the dash plenum panel inside the passenger compartment prior to instrument panel roll-up. Rear Blower Motor Resistor Remove/Install The rear blower motor resistor and bracket are mounted in the right rear corner of the rear overhead A/C unit upper housing cover. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications > Page 5033 Blower Motor Resistor: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications > Page 5034 Blower Motor Resistor: Description and Operation SYSTEM DESCRIPTION Front Blower Motor Resistor - Factory Installation During vehicle assembly, the blower motor resistor is mounted to the dash plenum panel inside the passenger compartment prior to instrument panel roll-up. However a resistor mounting plate has been designed so that the resistor can be removed through an access hole in the cowl plenum panel just below the windshield. It can be accessed by removing the cowl plenum cover/grille panel. 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 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 through the high speed blower motor relay The blower motor resistor cannot be repaired and, if faulty or damaged, it must be replaced. Rear The blower motor resistor for the optional rear overhead 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 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications > Page 5035 Blower Motor Resistor: Testing and Inspection Both the front blower motor resistor and the optional rear overhead A/C unit blower motor resistor can be diagnosed using the procedure that follows. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications > Page 5036 Blower Motor Resistor: Service and Repair FRONT REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cowl plenum cover/grille panel from the cowl top. Blower Motor Resistor Remove/Install 3. Reach through the cowl plenum access hole to remove the two hex screws that secure the front blower motor resistor to the cowl plenum panel. 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. Unplug the front blower motor resistor from the wire harness connector. 6. 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 cowl plenum panel by feeding the resistor and wire harness back through the cowl plenum access hole. 3. Install and tighten the two screws that secure the front blower motor resistor to the cowl plenum panel. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 4. Reinstall the cowl plenum cover/grille panel to the cowl top. 5. Connect the battery negative cable. REAR The rear blower motor resistor is used only on models with the optional rear overhead A/C unit. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the headliner from the passenger compartment of the vehicle. Rear Overhead A/C Drain Hose Remove/Install 3. Disconnect the B-pillar drain hoses from the way fittings on each side of the rear overhead A/C unit. 4. Remove the nine screws that secure the lower housing cover to the rear overhead A/C unit. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications > Page 5037 Rear Overhead A/C Unit Lower Housing Cover Remove/Install 5. Release the lower housing cover snap retainer near the center of the outlet side (rear) of the rear overhead A/C unit. 6. Feed the rear blower motor switch wire harness and connector through the hole in the right end of the rear overhead A/C unit lower housing cover while removing the cover from the unit. Rear Blower Motor Resistor Remove/Install 7. Disengage the rear blower motor resistor wire harness connector retainer from the mounting hole in the right rear corner of the rear overhead A/C unit upper housing cover. 8. Unplug the rear blower motor resistor wire harness connector. 9. Remove the screw that secures the rear blower motor resistor bracket to the rear overhead A/C unit upper housing cover. 10. Remove the rear blower motor resistor and bracket as a unit from the rear overhead A/C unit. INSTALLATION 1. Position the rear blower motor resistor and bracket in the right rear corner of the rear overhead A/C unit upper housing cover and secure it with the mounting screw. Tighten the mounting screw to 2.2 Nm (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 overhead A/C unit upper housing cover. 4. Feed the rear blower motor switch wire harness and connector through the hole in the right end of the rear overhead A/C unit lower housing cover while positioning the cover to the unit. 5. Be certain that the lower housing cover snap retainer near the center of the outlet side (rear) of the rear overhead A/C unit is engaged. 6. Install the nine screws that secure the lower housing cover to the rear overhead A/C unit. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 7. Connect the B-pillar drain hoses to the way fittings on each side of the rear overhead A/C unit. 8. Reinstall the headliner to the passenger compartment of the vehicle. 9. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations Blower Motor Switch: Locations Rear Blower Motor Switch Remove/Install The blower motor switch is mounted in the heater-A/C control panel Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 5041 Blower Motor Switch: Description and Operation SYSTEM DESCRIPTION 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. Rear The optional rear overhead A/C unit blower motor is controlled by a four position rotary-type blower motor switch, mounted by a snap fit in a hole in the headliner over the right front seat back. The switch allows the selection of one of three blower motor speeds and an Off position. The blower motor switch directs the blower motor ground path through the blower motor resistor. The blower motor switch cannot be repaired and, if faulty or damaged, the entire switch unit must be replaced. The blower motor switch has a replaceable incandescent-type illumination lamp bulb. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 5042 Blower Motor Switch: Testing and Inspection Front WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check for battery voltage at the 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. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the heater-A/C control from the instrument panel. Check for continuity between the ground circuit cavity of the heater-A/C control wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 3. With the heater-A/C control wire harness connector unplugged, place the heater-A/C mode control switch knob to any position except the Off position. Check for continuity between the ground circuit terminal and each of the blower motor driver circuit terminals of the heater-A/C control as you move the blower motor switch knob to each of the four speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the blower driver circuits between the heater-A/C control connector and the blower motor resistor as required. If not OK, replace the faulty heater-A/C control unit. Rear 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the rear blower motor switch from the headliner. Check for continuity between the ground circuit cavity of the rear blower motor switch wire harness connector and a good ground. There should be continuity If OK, go to Step 2. If not OK, repair the open circuit to ground as required. 2. With the rear blower motor switch wire harness connector unplugged, place the rear blower motor switch knob to any position except the Off position. Check for continuity between the ground circuit terminal and each of the blower motor driver circuit terminals of the rear blower motor switch as you move the blower motor switch knob to each of the three speed positions. There should be continuity at each driver circuit terminal in only one blowermotor switch speed position. If OK, test and repair the rear blower driver circuits between the rear blower motor switch wire harness connector and the blower motor resistor as required. If not OK, replace the faulty rear blower motor switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 5043 Blower Motor Switch: Service and Repair The rear blower motor switch is used only on models with the optional rear overhead air conditioning unit. REMOVAL 1. Disconnect and isolate the battery negative cable. Rear Blower Motor Switch Remove/Install 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 blower motor switch 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 1. Plug the wire harness connector into the back of the rear blower motor switch. 2. Check 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Electrical Specifications Compressor Clutch: Electrical Specifications Amperage Draw 2.0 - 3.9 A @ 12 Volts +/- 0.5 Volts @ 70 Deg F Air Gap 0.016 - 0.031 in Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Electrical Specifications > Page 5049 Compressor Clutch: Mechanical Specifications Compressor Shaft Hex Nut 10.5 ft.lb Clutch Air Gap 0.016 - 0.031 in Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5050 Compressor Clutch: Locations Power Distribution Center (PDC) The A/C relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5051 A/C Compressor Clutch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5052 Compressor Clutch: Description and Operation Compressor Clutch - Typical SYSTEM DESCRIPTION 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 electronic cycling clutch switch, the low pressure cut-off switch, the high pressure cut-off switch, the compressor clutch relay, and the Power-train Control Module (PCM). The PCM may delay compressor clutch engagement for up to thirty seconds. Power Distribution Center (PDC) AIR CONDITIONING (A/C) CLUTCH RELAY- PCM OUTPUT The A/C relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. The Powertrain Control Module (PCM) activates the A/C compressor through the A/C clutch relay. The PCM regulates A/C compressor operation by switching the ground circuit for the A/C clutch relay on and off. When the PCM receives a request for A/C from A/C evaporator switch, it will adjust idle air control (IAC) motor position. This is done to increase idle speed. The PCM will then activate the A/C clutch through the A/C clutch relay. The PCM adjusts idle air control (IAC) stepper motor position to compensate for increased engine load from the A/C compressor. By switching the ground path for the relay on and off, the PCM is able to cycle the A/C compressor clutch. This is based on changes in engine operating conditions. If; during A/C operation, the PCM senses low idle speeds or a wide open throttle condition, it will de-energize the relay. This Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5053 prevents A/C clutch engagement. The relay will remain de-energized until the idle speed increases or the wide open throttle condition exceeds 15 seconds or no longer exists. The PCM will also de-energize the relay if coolant temperature exceeds 125°C (257°F). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5054 Compressor Clutch: Service and Repair The refrigerant system can remain fully-charged during compressor clutch, pulley, or coil replacement. The compressor clutch can be serviced in the vehicle. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the serpentine drive belt. 3. Unplug the compressor clutch coil wire harness connector. 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. External Snap Ring Remove 6. Remove the external front housing snap ring with snap ring pliers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5055 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). 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5056 Clutch Coil Lead Wire Harness 9. Remove the screw and retainer from the clutch coil lead wire harness on the compressor front housing. 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. 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5057 Rotor Installer Set 4. Thread the handle (Special Tool 6464 in Kit 6460) into the driver (Special Tool 6143 in Kit 6460). 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5058 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.). 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. Reverse the remaining removal procedures to complete the installation. 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 heater-A/C 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Testing and Inspection Compressor Clutch Coil: Testing and Inspection 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 - Electronic clutch cycling switch - High pressure cut-off switch - Low pressure cut-off switch - 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Component Locations Compressor Clutch Relay: Component Locations Power Distribution Center The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 5066 Compressor Clutch Relay: Connector Locations Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 5067 A/C Compressor Clutch Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Description and Operation > A/C Compressor Clutch Relay Description Compressor Clutch Relay: Description and Operation A/C Compressor Clutch Relay Description SYSTEM DESCRIPTION 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 electronic cycling clutch switch, the low pressure cut-off switch, and the high pressure cut-off switch. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Description and Operation > A/C Compressor Clutch Relay Description > Page 5070 Compressor Clutch Relay: Description and Operation A/C Compressor Clutch Relay-PCM Output Power Distribution Center (PDC) AIR CONDITIONING (A/C) CLUTCH RELAY-PCM OUTPUT The A/C relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. The Powertrain Control Module (PCM) activates the A/C compressor through the A/C clutch relay. The PCM regulates A/C compressor operation by switching the ground circuit for the A/C clutch relay on and off. When the PCM receives a request for A/C from A/C evaporator switch, it will adjust idle air control (IAC) motor position. This is done to increase idle speed. The PCM will then activate the A/C clutch through the A/C clutch relay. The PCM adjusts idle air control (IAC) stepper motor position to compensate for increased engine load from the A/C compressor. By switching the ground path for the relay on and off, the PCM is able to cycle the A/C compressor clutch. This is based on changes in engine operating conditions. If; during A/C operation, the PCM senses low idle speeds or a wide open throttle condition, it will de-energize the relay. This prevents A/C clutch engagement. The relay will remain de-energized until the idle speed increases or the wide open throttle condition exceeds 15 seconds or no longer exists. The PCM will also de-energize the relay if coolant temperature exceeds 125°C (257°F). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Description and Operation > Page 5071 Compressor Clutch Relay: Testing and Inspection Relay Test Compressor Clutch Relay 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 Relay Circuit Test in the Diagnosis and Testing. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Description and Operation > Page 5072 Compressor Clutch Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 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. 5. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 24-013-01 > Sep > 01 > A/C - Warm Air From Vents at Idle Condenser HVAC: Customer Interest A/C - Warm Air From Vents at Idle NUMBER: 24-013-01 GROUP: Heating & A/C DATE: September 28, 2001 SUBJECT: Warm air blows from panel outlets with A/C on at idle. OVERVIEW: This bulletin involves installing an electric cooling fan kit. MODELS: 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES NOT EQUIPPED WITH DAYTIME RUNNING LAMPS. SYMPTOM/CONDITION: Some 1998 - 1999 (DN) Durangos may blow warm air out the instrument panel outlets while the A/C is ON in conditions of ambient temperatures exceeding 30° C. (86° F.) and the vehicle not in motion. In conditions of "stop-and-go" traffic or while idling in high ambient temperatures, the A/C high side pressures may exceed the high-pressure switch shut off of 450 - 490 psi. causing the A/C compressor to disengage. The compressor will re-engage once the high side pressure drops below 270 - 330 psi. The root cause of the problem may be related to inadequate airflow through the A/C condenser in high ambient temperatures while the vehicle is not in motion. DIAGNOSIS: NOTE: THIS PROCEDURE WILL NOT CORRECT A CONDITION WHERE THE A/C COMPRESSOR DISENGAGES DUE TO EXCESSIVE HIGH SIDE PRESSURE WHILE THE VEHICLE IS IN MOTION. NOR WILL THIS PROCEDURE CORRECT ANY A/C PERFORMANCE COMPLAINT OTHER THAN THE LOSS OF A/C IN "STOP-AND-GO" TRAFFIC OR IDLE CONDITIONS WHILE IN HIGH AMBIENT TEMPERATURES AND HUMIDITY. Verify A/C system operation by performing an A/C Performance Test. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), pages 24-13 through 24-16. If the vehicle passes the A/C performance test as identified in the 1999 Durango Service Manual, yet the customer complains that warm air discharges out the panel ducts with the A/C ON with the vehicle NOT in motion, install the Electric Cooling Fan Kit. If the vehicle did not pass the performance test, repair the vehicle as necessary. This procedure WILL NOT be able to correct the condition. PARTS REQUIRED: NOTE: DUE TO THE ELECTRICAL LOAD REQUIREMENTS OF THE ELECTRIC COOLING FAN, THE 136 AMP GENERATOR IS REQUIRED ON ALL VEHICLES. SOME 1999 MODELS MAY HAVE THE 136 AMP GENERATOR. 1999 MODELS EQUIPPED WITH TRAILER TOW PACKAGE (SALES CODE AHC) ARE EQUIPPED WITH THE 136 AMP GENERATOR. TO ENSURE THAT 1999 MODELS ARE EQUIPPED WITH THE 136 AMP GENERATOR, VERIFY THAT THE PART NUMBER ON THE GENERATOR IS 56028920AA. ALL MODELS NOT EQUIPPED WITH THE 136 AMP GENERATOR MUST USE KIT 05019227AB. REPAIR PROCEDURE: Detailed instructions are included in the parts kit. Refer to the instructions for the Repair Procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 24-013-01 > Sep > 01 > A/C - Warm Air From Vents at Idle > Page 5081 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 24-013-01 > Sep > 01 > A/C - Warm Air From Vents at Idle Condenser HVAC: All Technical Service Bulletins A/C - Warm Air From Vents at Idle NUMBER: 24-013-01 GROUP: Heating & A/C DATE: September 28, 2001 SUBJECT: Warm air blows from panel outlets with A/C on at idle. OVERVIEW: This bulletin involves installing an electric cooling fan kit. MODELS: 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES NOT EQUIPPED WITH DAYTIME RUNNING LAMPS. SYMPTOM/CONDITION: Some 1998 - 1999 (DN) Durangos may blow warm air out the instrument panel outlets while the A/C is ON in conditions of ambient temperatures exceeding 30° C. (86° F.) and the vehicle not in motion. In conditions of "stop-and-go" traffic or while idling in high ambient temperatures, the A/C high side pressures may exceed the high-pressure switch shut off of 450 - 490 psi. causing the A/C compressor to disengage. The compressor will re-engage once the high side pressure drops below 270 - 330 psi. The root cause of the problem may be related to inadequate airflow through the A/C condenser in high ambient temperatures while the vehicle is not in motion. DIAGNOSIS: NOTE: THIS PROCEDURE WILL NOT CORRECT A CONDITION WHERE THE A/C COMPRESSOR DISENGAGES DUE TO EXCESSIVE HIGH SIDE PRESSURE WHILE THE VEHICLE IS IN MOTION. NOR WILL THIS PROCEDURE CORRECT ANY A/C PERFORMANCE COMPLAINT OTHER THAN THE LOSS OF A/C IN "STOP-AND-GO" TRAFFIC OR IDLE CONDITIONS WHILE IN HIGH AMBIENT TEMPERATURES AND HUMIDITY. Verify A/C system operation by performing an A/C Performance Test. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), pages 24-13 through 24-16. If the vehicle passes the A/C performance test as identified in the 1999 Durango Service Manual, yet the customer complains that warm air discharges out the panel ducts with the A/C ON with the vehicle NOT in motion, install the Electric Cooling Fan Kit. If the vehicle did not pass the performance test, repair the vehicle as necessary. This procedure WILL NOT be able to correct the condition. PARTS REQUIRED: NOTE: DUE TO THE ELECTRICAL LOAD REQUIREMENTS OF THE ELECTRIC COOLING FAN, THE 136 AMP GENERATOR IS REQUIRED ON ALL VEHICLES. SOME 1999 MODELS MAY HAVE THE 136 AMP GENERATOR. 1999 MODELS EQUIPPED WITH TRAILER TOW PACKAGE (SALES CODE AHC) ARE EQUIPPED WITH THE 136 AMP GENERATOR. TO ENSURE THAT 1999 MODELS ARE EQUIPPED WITH THE 136 AMP GENERATOR, VERIFY THAT THE PART NUMBER ON THE GENERATOR IS 56028920AA. ALL MODELS NOT EQUIPPED WITH THE 136 AMP GENERATOR MUST USE KIT 05019227AB. REPAIR PROCEDURE: Detailed instructions are included in the parts kit. Refer to the instructions for the Repair Procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 24-013-01 > Sep > 01 > A/C - Warm Air From Vents at Idle > Page 5087 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 5088 Condenser HVAC: Specifications Upper Radiator Crossmember Nut 95 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 5089 Condenser HVAC: Locations Condenser Remove/Install The condenser is located in the air flow in front of the engine cooling radiator. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 5090 Condenser HVAC: Description and Operation SYSTEM DESCRIPTION The condenser is located in the air flow in front of the engine cooling radiator. 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 5091 Condenser HVAC: Service and Repair WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. 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. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 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 radiator from the engine compartment. Condenser Remove/Install 7. Remove the two screws that secure the condenser to the outside of the upper radiator crossmember. 8. Tilt the top of the radiator and fan shroud module towards the engine, using care not to damage the radiator fins on the engine cooling fan. 9. With the radiator and fan shroud module tilted, carefully lift the condenser upwards until the lower condenser mounts are clear of the isolators in the lower crossmember. 10. Remove the condenser from the vehicle. INSTALLATION 1. With the radiator and fan shroud module tilted towards the engine, carefully position the lower condenser mounts in the lower crossmember isolators. 2. Reinstall the two screws that secure the condenser to the outside of the upper radiator crossmember and tighten to 10.7 Nm (95 in. lbs.). 3. Reinstall the radiator to the engine compartment. 4. Reinstall the two screws that secure the radiator and fan shroud module to the inside of the upper radiator crossmember. 5. 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. 6. 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. 7. Check that all of the condenser and radiator air seals are in their proper locations. 8. Connect the battery negative cable. 9. Evacuate the refrigerant system. 10. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Technical Service Bulletins > Customer Interest for Condenser Fan: > 24-013-01 > Sep > 01 > A/C - Warm Air From Vents at Idle Condenser Fan: Customer Interest A/C - Warm Air From Vents at Idle NUMBER: 24-013-01 GROUP: Heating & A/C DATE: September 28, 2001 SUBJECT: Warm air blows from panel outlets with A/C on at idle. OVERVIEW: This bulletin involves installing an electric cooling fan kit. MODELS: 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES NOT EQUIPPED WITH DAYTIME RUNNING LAMPS. SYMPTOM/CONDITION: Some 1998 - 1999 (DN) Durangos may blow warm air out the instrument panel outlets while the A/C is ON in conditions of ambient temperatures exceeding 30° C. (86° F.) and the vehicle not in motion. In conditions of "stop-and-go" traffic or while idling in high ambient temperatures, the A/C high side pressures may exceed the high-pressure switch shut off of 450 - 490 psi. causing the A/C compressor to disengage. The compressor will re-engage once the high side pressure drops below 270 - 330 psi. The root cause of the problem may be related to inadequate airflow through the A/C condenser in high ambient temperatures while the vehicle is not in motion. DIAGNOSIS: NOTE: THIS PROCEDURE WILL NOT CORRECT A CONDITION WHERE THE A/C COMPRESSOR DISENGAGES DUE TO EXCESSIVE HIGH SIDE PRESSURE WHILE THE VEHICLE IS IN MOTION. NOR WILL THIS PROCEDURE CORRECT ANY A/C PERFORMANCE COMPLAINT OTHER THAN THE LOSS OF A/C IN "STOP-AND-GO" TRAFFIC OR IDLE CONDITIONS WHILE IN HIGH AMBIENT TEMPERATURES AND HUMIDITY. Verify A/C system operation by performing an A/C Performance Test. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), pages 24-13 through 24-16. If the vehicle passes the A/C performance test as identified in the 1999 Durango Service Manual, yet the customer complains that warm air discharges out the panel ducts with the A/C ON with the vehicle NOT in motion, install the Electric Cooling Fan Kit. If the vehicle did not pass the performance test, repair the vehicle as necessary. This procedure WILL NOT be able to correct the condition. PARTS REQUIRED: NOTE: DUE TO THE ELECTRICAL LOAD REQUIREMENTS OF THE ELECTRIC COOLING FAN, THE 136 AMP GENERATOR IS REQUIRED ON ALL VEHICLES. SOME 1999 MODELS MAY HAVE THE 136 AMP GENERATOR. 1999 MODELS EQUIPPED WITH TRAILER TOW PACKAGE (SALES CODE AHC) ARE EQUIPPED WITH THE 136 AMP GENERATOR. TO ENSURE THAT 1999 MODELS ARE EQUIPPED WITH THE 136 AMP GENERATOR, VERIFY THAT THE PART NUMBER ON THE GENERATOR IS 56028920AA. ALL MODELS NOT EQUIPPED WITH THE 136 AMP GENERATOR MUST USE KIT 05019227AB. REPAIR PROCEDURE: Detailed instructions are included in the parts kit. Refer to the instructions for the Repair Procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Technical Service Bulletins > Customer Interest for Condenser Fan: > 24-013-01 > Sep > 01 > A/C - Warm Air From Vents at Idle > Page 5100 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser Fan: > 24-013-01 > Sep > 01 > A/C - Warm Air From Vents at Idle Condenser Fan: All Technical Service Bulletins A/C - Warm Air From Vents at Idle NUMBER: 24-013-01 GROUP: Heating & A/C DATE: September 28, 2001 SUBJECT: Warm air blows from panel outlets with A/C on at idle. OVERVIEW: This bulletin involves installing an electric cooling fan kit. MODELS: 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES NOT EQUIPPED WITH DAYTIME RUNNING LAMPS. SYMPTOM/CONDITION: Some 1998 - 1999 (DN) Durangos may blow warm air out the instrument panel outlets while the A/C is ON in conditions of ambient temperatures exceeding 30° C. (86° F.) and the vehicle not in motion. In conditions of "stop-and-go" traffic or while idling in high ambient temperatures, the A/C high side pressures may exceed the high-pressure switch shut off of 450 - 490 psi. causing the A/C compressor to disengage. The compressor will re-engage once the high side pressure drops below 270 - 330 psi. The root cause of the problem may be related to inadequate airflow through the A/C condenser in high ambient temperatures while the vehicle is not in motion. DIAGNOSIS: NOTE: THIS PROCEDURE WILL NOT CORRECT A CONDITION WHERE THE A/C COMPRESSOR DISENGAGES DUE TO EXCESSIVE HIGH SIDE PRESSURE WHILE THE VEHICLE IS IN MOTION. NOR WILL THIS PROCEDURE CORRECT ANY A/C PERFORMANCE COMPLAINT OTHER THAN THE LOSS OF A/C IN "STOP-AND-GO" TRAFFIC OR IDLE CONDITIONS WHILE IN HIGH AMBIENT TEMPERATURES AND HUMIDITY. Verify A/C system operation by performing an A/C Performance Test. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), pages 24-13 through 24-16. If the vehicle passes the A/C performance test as identified in the 1999 Durango Service Manual, yet the customer complains that warm air discharges out the panel ducts with the A/C ON with the vehicle NOT in motion, install the Electric Cooling Fan Kit. If the vehicle did not pass the performance test, repair the vehicle as necessary. This procedure WILL NOT be able to correct the condition. PARTS REQUIRED: NOTE: DUE TO THE ELECTRICAL LOAD REQUIREMENTS OF THE ELECTRIC COOLING FAN, THE 136 AMP GENERATOR IS REQUIRED ON ALL VEHICLES. SOME 1999 MODELS MAY HAVE THE 136 AMP GENERATOR. 1999 MODELS EQUIPPED WITH TRAILER TOW PACKAGE (SALES CODE AHC) ARE EQUIPPED WITH THE 136 AMP GENERATOR. TO ENSURE THAT 1999 MODELS ARE EQUIPPED WITH THE 136 AMP GENERATOR, VERIFY THAT THE PART NUMBER ON THE GENERATOR IS 56028920AA. ALL MODELS NOT EQUIPPED WITH THE 136 AMP GENERATOR MUST USE KIT 05019227AB. REPAIR PROCEDURE: Detailed instructions are included in the parts kit. Refer to the instructions for the Repair Procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser Fan: > 24-013-01 > Sep > 01 > A/C - Warm Air From Vents at Idle > Page 5106 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow Technical Service Bulletin # 24-20-99A Date: 991217 A/C Bi-Level Mode - Unbalanced Vent Air Flow NUMBER: 24-20-99 Rev. A GROUP: Heating & A/C DATE: Dec. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-20-99, DATED OCT. 8, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL PARTS AND PROCEDURES. SUBJECT: While In Bi-level Mode, Air Flow From Panel Vents Is Less Than That Of The Floor Vents OVERVIEW: This bulletin involves installing a panel-defrost control lever **and a retaining push nut**. MODELS: 1997 - 2000 (AN) Dakota 1998 - 2000 (DN) Durango SYMPTOM/CONDITION: While in bi-level mode, air flow from panel vents is less than that of the floor vents. DIAGNOSIS: While in bi-level mode, there should be an approximately 50% air distribution between the panel vents and the heater outlets. Operate the heater A/C system in panel, bi-level, and heater modes. If the air distribution is good in the heater and panel modes, but when in bi-level mode, air distribution to the heater outlets is greater than the panel outlets, perform the Repair Procedure. PARTS REQUIRED: 1 03847858 Lever, Panel-Defrost Control **1 06031147 Push Nut** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-50-33-91 1.4 Hrs. FAILURE CODE: P8 - New Part Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: REFER TO THE APPROPRIATE SERVICE MANUAL, GROUP 8M-PASSIVE RESTRAINT SYSTEMS, BEFORE ATTEMPTING TO SERVICE THE HEATER-A/C HOUSING ASSEMBLY. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Rotate the steering wheel so that the steering wheel is in an upside down position then, remove the ignition key to lock the steering wheel in this position. 2. Position the front seats in the full rearward position. 3. Disconnect and isolate the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow > Page 5115 4. Using a trim stick, pry up the door sill trim cover from the door sill on both sides of the vehicle (Figure 1) and separate the cover from the vehicle. 5. Remove the two screws that attach the cowl trim cover to the cowl (Figure 2). 6. Using a trim stick pry the cowl trim cover away from the cowl to disengage the clips. 7. Separate the cowl trim cover from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow > Page 5116 8. Remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement (Figure 3). 9. Using a trim stick, disengage the snap clip retainers from the receptacles in the instrument panel by gently prying the upper edge of the steering column opening cover away from the instrument panel. Pry on the cover just below the instrument cluster bezel on each side of the steering column. 10. Remove the steering column opening cover from the instrument panel. 11. Remove the four screws that secure the lower reinforcement to the instrument panel (Figure 4). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow > Page 5117 12. If the vehicle is equipped with a column shift automatic transmission, put the transmission range selector into Park. Then, remove the PRNDL drive cable from the PRNDL lever (Figure 5). Push the tabs on top of the cable retainer, then squeeze the sides to remove the retainer from the column. 13. Disconnect the driver side airbag module wire harness connector from the instrument panel wire harness near the instrument panel lower reinforcement. 14. If the vehicle is so equipped, disconnect the overdrive lockout switch wire harness connector from the instrument panel wire harness near the instrument panel lower reinforcement. 15. Remove the tilt lever from the steering column. 16. Remove the lower and upper steering column shrouds. 17. Disconnect the multifunction switch, speed control switch, and ignition switch wiring harnesses (Figure 6). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow > Page 5118 18. Remove the steering column mounting nuts (Figure 7) and lower the steering column to the floor. 19. Remove the screw from the center of the headlamp and dash to instrument panel bulkhead wire harness connectors and disconnect the connectors. 20. Disconnect the two body wire harness connectors from the two instrument panel wire harness connectors that are secured to the outboard side of the instrument panel bulkhead connectors. 21. Disconnect the three wire harness connectors (one from the body wire harness and two from the headlamp and dash wire harness) from the three junction block connector receptacles located closest to the dash panel. 22. Disconnect the instrument panel wire harness connector form the stop lamp switch connector receptacle. 23. Remove the park brake release rod from the pedal assembly (Figure 8). 24. Pull the floor carpet back from the front of the floor panel transmission tunnel far enough to access the center support bracket mounting screws. 25. Remove the two screws that secure the center support bracket to the instrument panel. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow > Page 5119 26. Remove the two screws on the left and one screw on the right that secure the instrument panel center support bracket to the Airbag Control Module (ACM) bracket on the floor panel transmission tunnel (Figure 9). 27. Remove the center support bracket from the instrument panel. 28. Disconnect the vacuum harness connector located near the left end of the heater-A/C housing 29. Remove the screw that secures the instrument panel wire harness ground eyelets to the left side of the Airbag Control Module (ACM) mount on the floor panel transmission tunnel. 30. Disconnect the instrument panel wire harness connector from the ACM connector receptacle. 31. Open the glove box. 32. Locate the three screws in the bottom of the glove box bin. Remove only the center screw. 33. Depress the two sides of the glove box bin far enough so that the rubber stop bumpers located on each side of the bin will clear the metal stops located on the bracket on each side of the glove box opening. 34. While holding the sides of the glove box bin depressed, roll the glove box downward until the stop bumpers are beyond the stops, then release the sides of the bin. 35. Grasp the upper outboard corner of the glove box door securely with both hands. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow > Page 5120 36. Pull the door firmly and quickly away from the instrument panel to unsnap the three glove box hinge hooks (Figure 10) from the three hinge pins on the instrument panel (Figure 11). 37. Reaching through the instrument panel glove box opening, perform the following: a) Disconnect the two halves of the radio antenna coaxial cable connector near the center of the lower instrument panel glove box opening. b) Disengage the antenna half of the radio antenna coaxial cable from the retainer clip near the outboard side of the lower instrument panel glove box opening. 38. From under the passenger side of the instrument panel , perform the following: a) If the vehicle is so equipped, disconnect the two instrument panel wire harness connectors from the infinity speaker amplifier connector receptacles on the right cowl side inner panel. b) Remove the nut that secures the instrument panel wire harness radio ground eyelet to the stud on the right cowl side inner panel. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow > Page 5121 39. Loosen the right and left instrument panel cowl side roll-down bracket screws about 6 mm (0.25 in.) (Figure 12). 40. Remove the five screws that secure the top of the instrument panel to the top of the dash panel, removing the center screw last. 41. Pull the lower instrument panel rearward until the right and left cowl side roll-down bracket screws are in the roll-down slot position of both brackets (Figure 13). 42. Roll down the instrument panel and install a temporary hook in the center hole on top of the instrument panel. Secure the other end of the hook to the center hole in the top of the dash panel. The hook should support the instrument panel in its rolled down position about 46 cm (18 in.) from the dash panel. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow > Page 5122 43. Using a trim stick, gently pry the panel-defrost door lever off the panel-defrost door pivot shaft (Figure 14). 44. Slide the panel-defrost door lever off from the panel-defrost door actuator link. 45. Slide the new panel-defrost door lever, p/n 03847858, onto the panel-defrost door actuator link. 46. Snap the panel-defrost door lever onto the panel-defrost door pivot shaft. 47. **Slide push nut p/n 06031147 over the end of the actuator link until the push nut is tight against the panel-defrost door actuator lever (Figure 15).** 48. Push the lower instrument panel forward until the right and left cowl side roll-down bracket screws are in the installed slot position of both brackets. 49. Remove the temporary hook from the instrument panel and roll the instrument panel up to the installed position against the dash panel. 50. Install and tighten the five screws that secure the top of the instrument panel to the top of the dash panel. Tighten the screws to 3.2 N.m (28 in. lbs.). 51. Tighten the right and left instrument panel cowl side roll-down bracket screws. Tighten the screws to 12 N.m (105 in. lbs.). 52. From under the passenger side of the instrument panel, perform the following: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow > Page 5123 a) If the vehicle is so equipped, reconnect the two instrument panel wire harness connectors to the Infinity speaker amplifier connector receptacles on the right cowl side inner panel. b) Install and tighten the nut that secures the instrument panel wire harness radio ground eyelet to the stud on the right cowl side inner panel. Tighten the nut to 3.9 N.m (35 in. lbs.). 52. Reaching through the instrument panel glove box opening, perform the following: a) Reconnect the two halves of the radio antenna coaxial cable connector near the center of the lower instrument panel glove box opening. b) Engage the antenna half of the radio antenna coaxial cable into the retainer clip near the outboard side of the lower instrument panel glove box opening. 53. Position the glove box to the instrument panel with the bin inserted in the glove box opening far enough so that the rubber stop bumpers, located on each side of the bin, are behind the metal stops located on the bracket on each side of the glove box opening. 54. Starting on the outboard side of the glove box, insert the first glove box hinge hook over the first hinge pin on the instrument panel. 55. Use a slight twisting action on the glove box door to insert the second hinge hook under the second hinge pin. 56. Finally, again using a slight twisting action on the glove box door, insert the last hinge hook under the last hinge pin. 57. Depress the two sides of the glove box bin far enough so that the rubber stop bumpers located on each side of the bin will clear the metal stops located on the bracket on each side of the glove box opening. Then, push the glove box up until the rubber stop bumpers are past the stop bumper brackets. 58. Install and tighten the center screw in the bottom of the glove box bin. Tighten the screw to 2.2 N.m (20 in. lbs.). 59. Close the glove box and then reopen it to check for proper hinge operation. 60. Install and tighten the screw that secures the instrument panel wire harness ground eyelets to the left side of the ACM mount on the floor panel transmission tunnel. Tighten the screw to 3.4 N.m (30 in. lbs.). 61. Reconnect the instrument panel wire harness connector to the ACM connector receptacle. 62. Position the center support bracket to the ACM bracket on the floor panel transmission tunnel. 63. Install and tighten the two screws on the left and the one screw on the right that secure the instrument panel center support bracket to the ACM bracket on the floor panel transmission tunnel. Tighten the screws to 12 N.m (105 in. lbs.). 64. Align the screw holes in the instrument panel with the mounting holes in the center support bracket. 65. Install and tighten the two screws that secure the center support bracket to the instrument panel. Tighten the screws to 12 N.m (105 in. lbs.). 66. Reposition the floor carpet on the front of the floor panel transmission tunnel to conceal the instrument panel center support bracket. 67. From under the driver side of the instrument panel, perform the following. a) Reconnect the headlamp and dash to instrument panel bulkhead wire harness connector Tighten the screw in the center of the connector to 3.5 N.m (31 in. lbs.). b) Reconnect the two body wire harness connectors to the two instrument panel wire harness connectors that are secured to the outboard side of the instrument panel bulkhead connector. c) Reconnect the three wire harness connectors (one from the body wire harness, and two from the headlamp and dash wire harness) to the three junction block connector receptacles located closest to the dash panel. d) Engage the linkage rod end into the lever on the back side of the park brake release handle and snap the plastic retainer clip that secures the rod to the lever over the linkage rod. e) Reconnect the instrument panel wire harness connector to the stop lamp switch connector receptacle. f) Reconnect the vacuum harness connector located near the left end of the heater-A/C housing. 68. Position the steering column to the panel bracket and attaching studs. Install the mounting nuts but only tighten them finger tight at this time. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow > Page 5124 69. Bounce the steering wheel lightly in a vertical motion to normalize the alignment. 70. Without influencing the new location of the steering column, tighten the passenger side rearward nut to 12 N.m (105 in. lbs.). 71. Next, tighten the front driver side nut to 12 N.m (105 in. lbs.). 72. Tighten the remaining steering column attaching nuts to 12 N.m (105 in. lbs.). 73. Reconnect the multifunction switch wiring harness. Tighten the assembly using a 7 mm socket to 2 N.m (17 in. lbs.). 74. Reconnect the speed control switch and ignition switch wire harnesses. 75. Install the lower upper steering column shrouds. 76. Install the tilt lever onto the steering column. 77. If the vehicle is equipped with a column shift automatic transmission, install the PRNDL drive cable. Place the gear selector into the Park position. If the indicator needs adjusting, turn the thumb screw on the cable retainer to adjust the cable. 78. If the vehicle is so equipped, reconnect the overdrive lockout switch wire harness connector to the instrument panel wire harness connector located near the instrument panel lower reinforcement. 79. Reconnect the driver side airbag module wire harness connector to the instrument panel wire harness connector located at the instrument panel lower reinforcement. 80. Position the lower reinforcement onto the instrument panel. 81. Install the four screws that secure the lower reinforcement to the instrument panel. Tighten the screws to 2.2 N.m (20 in. lbs.). 82. Position the steering column opening cover to the instrument panel. 83. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel. 84. 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. 85. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Tighten the screws to 2.2 N.m (20 in. lbs.). 86. Position the cowl trim cover onto the cowl. 87. Press the cowl trim cover into place to engage the retaining clips. Then, install and tighten the two retaining screws. 88. Position the front edge of the door sill trim cover over the cowl trim cover and align the tabs. 89. Align door sill trim cover and press into place. 90. Adjust the temperature control cable. Refer the appropriate Service Manual, Group 24 for information regarding Temperature Control Cable adjustment. 91. Connect the battery negative cable and reset the clock on the radio. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow Technical Service Bulletin # 24-20-99A Date: 991217 A/C Bi-Level Mode - Unbalanced Vent Air Flow NUMBER: 24-20-99 Rev. A GROUP: Heating & A/C DATE: Dec. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-20-99, DATED OCT. 8, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL PARTS AND PROCEDURES. SUBJECT: While In Bi-level Mode, Air Flow From Panel Vents Is Less Than That Of The Floor Vents OVERVIEW: This bulletin involves installing a panel-defrost control lever **and a retaining push nut**. MODELS: 1997 - 2000 (AN) Dakota 1998 - 2000 (DN) Durango SYMPTOM/CONDITION: While in bi-level mode, air flow from panel vents is less than that of the floor vents. DIAGNOSIS: While in bi-level mode, there should be an approximately 50% air distribution between the panel vents and the heater outlets. Operate the heater A/C system in panel, bi-level, and heater modes. If the air distribution is good in the heater and panel modes, but when in bi-level mode, air distribution to the heater outlets is greater than the panel outlets, perform the Repair Procedure. PARTS REQUIRED: 1 03847858 Lever, Panel-Defrost Control **1 06031147 Push Nut** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-50-33-91 1.4 Hrs. FAILURE CODE: P8 - New Part Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: REFER TO THE APPROPRIATE SERVICE MANUAL, GROUP 8M-PASSIVE RESTRAINT SYSTEMS, BEFORE ATTEMPTING TO SERVICE THE HEATER-A/C HOUSING ASSEMBLY. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Rotate the steering wheel so that the steering wheel is in an upside down position then, remove the ignition key to lock the steering wheel in this position. 2. Position the front seats in the full rearward position. 3. Disconnect and isolate the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 5130 4. Using a trim stick, pry up the door sill trim cover from the door sill on both sides of the vehicle (Figure 1) and separate the cover from the vehicle. 5. Remove the two screws that attach the cowl trim cover to the cowl (Figure 2). 6. Using a trim stick pry the cowl trim cover away from the cowl to disengage the clips. 7. Separate the cowl trim cover from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 5131 8. Remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement (Figure 3). 9. Using a trim stick, disengage the snap clip retainers from the receptacles in the instrument panel by gently prying the upper edge of the steering column opening cover away from the instrument panel. Pry on the cover just below the instrument cluster bezel on each side of the steering column. 10. Remove the steering column opening cover from the instrument panel. 11. Remove the four screws that secure the lower reinforcement to the instrument panel (Figure 4). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 5132 12. If the vehicle is equipped with a column shift automatic transmission, put the transmission range selector into Park. Then, remove the PRNDL drive cable from the PRNDL lever (Figure 5). Push the tabs on top of the cable retainer, then squeeze the sides to remove the retainer from the column. 13. Disconnect the driver side airbag module wire harness connector from the instrument panel wire harness near the instrument panel lower reinforcement. 14. If the vehicle is so equipped, disconnect the overdrive lockout switch wire harness connector from the instrument panel wire harness near the instrument panel lower reinforcement. 15. Remove the tilt lever from the steering column. 16. Remove the lower and upper steering column shrouds. 17. Disconnect the multifunction switch, speed control switch, and ignition switch wiring harnesses (Figure 6). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 5133 18. Remove the steering column mounting nuts (Figure 7) and lower the steering column to the floor. 19. Remove the screw from the center of the headlamp and dash to instrument panel bulkhead wire harness connectors and disconnect the connectors. 20. Disconnect the two body wire harness connectors from the two instrument panel wire harness connectors that are secured to the outboard side of the instrument panel bulkhead connectors. 21. Disconnect the three wire harness connectors (one from the body wire harness and two from the headlamp and dash wire harness) from the three junction block connector receptacles located closest to the dash panel. 22. Disconnect the instrument panel wire harness connector form the stop lamp switch connector receptacle. 23. Remove the park brake release rod from the pedal assembly (Figure 8). 24. Pull the floor carpet back from the front of the floor panel transmission tunnel far enough to access the center support bracket mounting screws. 25. Remove the two screws that secure the center support bracket to the instrument panel. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 5134 26. Remove the two screws on the left and one screw on the right that secure the instrument panel center support bracket to the Airbag Control Module (ACM) bracket on the floor panel transmission tunnel (Figure 9). 27. Remove the center support bracket from the instrument panel. 28. Disconnect the vacuum harness connector located near the left end of the heater-A/C housing 29. Remove the screw that secures the instrument panel wire harness ground eyelets to the left side of the Airbag Control Module (ACM) mount on the floor panel transmission tunnel. 30. Disconnect the instrument panel wire harness connector from the ACM connector receptacle. 31. Open the glove box. 32. Locate the three screws in the bottom of the glove box bin. Remove only the center screw. 33. Depress the two sides of the glove box bin far enough so that the rubber stop bumpers located on each side of the bin will clear the metal stops located on the bracket on each side of the glove box opening. 34. While holding the sides of the glove box bin depressed, roll the glove box downward until the stop bumpers are beyond the stops, then release the sides of the bin. 35. Grasp the upper outboard corner of the glove box door securely with both hands. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 5135 36. Pull the door firmly and quickly away from the instrument panel to unsnap the three glove box hinge hooks (Figure 10) from the three hinge pins on the instrument panel (Figure 11). 37. Reaching through the instrument panel glove box opening, perform the following: a) Disconnect the two halves of the radio antenna coaxial cable connector near the center of the lower instrument panel glove box opening. b) Disengage the antenna half of the radio antenna coaxial cable from the retainer clip near the outboard side of the lower instrument panel glove box opening. 38. From under the passenger side of the instrument panel , perform the following: a) If the vehicle is so equipped, disconnect the two instrument panel wire harness connectors from the infinity speaker amplifier connector receptacles on the right cowl side inner panel. b) Remove the nut that secures the instrument panel wire harness radio ground eyelet to the stud on the right cowl side inner panel. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 5136 39. Loosen the right and left instrument panel cowl side roll-down bracket screws about 6 mm (0.25 in.) (Figure 12). 40. Remove the five screws that secure the top of the instrument panel to the top of the dash panel, removing the center screw last. 41. Pull the lower instrument panel rearward until the right and left cowl side roll-down bracket screws are in the roll-down slot position of both brackets (Figure 13). 42. Roll down the instrument panel and install a temporary hook in the center hole on top of the instrument panel. Secure the other end of the hook to the center hole in the top of the dash panel. The hook should support the instrument panel in its rolled down position about 46 cm (18 in.) from the dash panel. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 5137 43. Using a trim stick, gently pry the panel-defrost door lever off the panel-defrost door pivot shaft (Figure 14). 44. Slide the panel-defrost door lever off from the panel-defrost door actuator link. 45. Slide the new panel-defrost door lever, p/n 03847858, onto the panel-defrost door actuator link. 46. Snap the panel-defrost door lever onto the panel-defrost door pivot shaft. 47. **Slide push nut p/n 06031147 over the end of the actuator link until the push nut is tight against the panel-defrost door actuator lever (Figure 15).** 48. Push the lower instrument panel forward until the right and left cowl side roll-down bracket screws are in the installed slot position of both brackets. 49. Remove the temporary hook from the instrument panel and roll the instrument panel up to the installed position against the dash panel. 50. Install and tighten the five screws that secure the top of the instrument panel to the top of the dash panel. Tighten the screws to 3.2 N.m (28 in. lbs.). 51. Tighten the right and left instrument panel cowl side roll-down bracket screws. Tighten the screws to 12 N.m (105 in. lbs.). 52. From under the passenger side of the instrument panel, perform the following: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 5138 a) If the vehicle is so equipped, reconnect the two instrument panel wire harness connectors to the Infinity speaker amplifier connector receptacles on the right cowl side inner panel. b) Install and tighten the nut that secures the instrument panel wire harness radio ground eyelet to the stud on the right cowl side inner panel. Tighten the nut to 3.9 N.m (35 in. lbs.). 52. Reaching through the instrument panel glove box opening, perform the following: a) Reconnect the two halves of the radio antenna coaxial cable connector near the center of the lower instrument panel glove box opening. b) Engage the antenna half of the radio antenna coaxial cable into the retainer clip near the outboard side of the lower instrument panel glove box opening. 53. Position the glove box to the instrument panel with the bin inserted in the glove box opening far enough so that the rubber stop bumpers, located on each side of the bin, are behind the metal stops located on the bracket on each side of the glove box opening. 54. Starting on the outboard side of the glove box, insert the first glove box hinge hook over the first hinge pin on the instrument panel. 55. Use a slight twisting action on the glove box door to insert the second hinge hook under the second hinge pin. 56. Finally, again using a slight twisting action on the glove box door, insert the last hinge hook under the last hinge pin. 57. Depress the two sides of the glove box bin far enough so that the rubber stop bumpers located on each side of the bin will clear the metal stops located on the bracket on each side of the glove box opening. Then, push the glove box up until the rubber stop bumpers are past the stop bumper brackets. 58. Install and tighten the center screw in the bottom of the glove box bin. Tighten the screw to 2.2 N.m (20 in. lbs.). 59. Close the glove box and then reopen it to check for proper hinge operation. 60. Install and tighten the screw that secures the instrument panel wire harness ground eyelets to the left side of the ACM mount on the floor panel transmission tunnel. Tighten the screw to 3.4 N.m (30 in. lbs.). 61. Reconnect the instrument panel wire harness connector to the ACM connector receptacle. 62. Position the center support bracket to the ACM bracket on the floor panel transmission tunnel. 63. Install and tighten the two screws on the left and the one screw on the right that secure the instrument panel center support bracket to the ACM bracket on the floor panel transmission tunnel. Tighten the screws to 12 N.m (105 in. lbs.). 64. Align the screw holes in the instrument panel with the mounting holes in the center support bracket. 65. Install and tighten the two screws that secure the center support bracket to the instrument panel. Tighten the screws to 12 N.m (105 in. lbs.). 66. Reposition the floor carpet on the front of the floor panel transmission tunnel to conceal the instrument panel center support bracket. 67. From under the driver side of the instrument panel, perform the following. a) Reconnect the headlamp and dash to instrument panel bulkhead wire harness connector Tighten the screw in the center of the connector to 3.5 N.m (31 in. lbs.). b) Reconnect the two body wire harness connectors to the two instrument panel wire harness connectors that are secured to the outboard side of the instrument panel bulkhead connector. c) Reconnect the three wire harness connectors (one from the body wire harness, and two from the headlamp and dash wire harness) to the three junction block connector receptacles located closest to the dash panel. d) Engage the linkage rod end into the lever on the back side of the park brake release handle and snap the plastic retainer clip that secures the rod to the lever over the linkage rod. e) Reconnect the instrument panel wire harness connector to the stop lamp switch connector receptacle. f) Reconnect the vacuum harness connector located near the left end of the heater-A/C housing. 68. Position the steering column to the panel bracket and attaching studs. Install the mounting nuts but only tighten them finger tight at this time. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 5139 69. Bounce the steering wheel lightly in a vertical motion to normalize the alignment. 70. Without influencing the new location of the steering column, tighten the passenger side rearward nut to 12 N.m (105 in. lbs.). 71. Next, tighten the front driver side nut to 12 N.m (105 in. lbs.). 72. Tighten the remaining steering column attaching nuts to 12 N.m (105 in. lbs.). 73. Reconnect the multifunction switch wiring harness. Tighten the assembly using a 7 mm socket to 2 N.m (17 in. lbs.). 74. Reconnect the speed control switch and ignition switch wire harnesses. 75. Install the lower upper steering column shrouds. 76. Install the tilt lever onto the steering column. 77. If the vehicle is equipped with a column shift automatic transmission, install the PRNDL drive cable. Place the gear selector into the Park position. If the indicator needs adjusting, turn the thumb screw on the cable retainer to adjust the cable. 78. If the vehicle is so equipped, reconnect the overdrive lockout switch wire harness connector to the instrument panel wire harness connector located near the instrument panel lower reinforcement. 79. Reconnect the driver side airbag module wire harness connector to the instrument panel wire harness connector located at the instrument panel lower reinforcement. 80. Position the lower reinforcement onto the instrument panel. 81. Install the four screws that secure the lower reinforcement to the instrument panel. Tighten the screws to 2.2 N.m (20 in. lbs.). 82. Position the steering column opening cover to the instrument panel. 83. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel. 84. 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. 85. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Tighten the screws to 2.2 N.m (20 in. lbs.). 86. Position the cowl trim cover onto the cowl. 87. Press the cowl trim cover into place to engage the retaining clips. Then, install and tighten the two retaining screws. 88. Position the front edge of the door sill trim cover over the cowl trim cover and align the tabs. 89. Align door sill trim cover and press into place. 90. Adjust the temperature control cable. Refer the appropriate Service Manual, Group 24 for information regarding Temperature Control Cable adjustment. 91. Connect the battery negative cable and reset the clock on the radio. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 5140 Control Assembly: Specifications Tighten the A/C Control screws to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 5141 Control Assembly: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 5142 Control Assembly: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. A/C Control = Bulb Number 74 Heater Control = Bulb Number 158 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Heater-A/C Control Assembly Operation Control Assembly: Testing and Inspection Heater-A/C Control Assembly Operation Satisfactory heater and air conditioner performance depends upon proper operation and adjustment of all operating controls and refrigeration system components. These inspections, tests, and adjustments should be used to locate the cause of a malfunction. Operation must be tested as described in the following sequence: 1. Move the temperature control knob quickly to the full hot and the full cold positions. There should be a distinct sound of the blend-air door hitting its stops within the heater-A/C housing at the end of knob travel in each direction, with no spring-back of the knob. If not OK, inspect the condition, routing, installation and adjustment of the temperature control cable. 2. Inspect and adjust the serpentine drive belt. 3. Start the engine and hold the idle speed at 1,300 rpm. 4. On vehicles with air conditioning, turn the temperature control knob to the extreme counterclockwise (Cool) position, and set the mode control switch knob in the Bi-Level (A/C) position. The outside (recirculation) air door should be open to out side air. If not OK, see Vacuum System in the Diagnosis and Testing. 5. Open the vehicle windows. Test the blower motor operation in all speeds. If not OK, see Blower Motor in the Diagnosis and Testing. Leave the blower motor switch knob in the highest speed position. 6. On vehicles with air conditioning, the compressor should be running and the air conditioning system in operation unless the ambient air temperature is below about -1° C (30° F). If not OK, see A/C Performance in the Diagnosis and Testing. 7. Check the mode control switch operation. The heater and air conditioner systems should respond as described in the owner's manual in the vehicle glove box to each mode selected. Reduce the engine speed to normal idle. The vacuum will be high at low idle and the vacuum actuators should respond quickly If not OK, see Vacuum System in the Diagnosis and Testing. 8. If the vacuum tests, and the electrical component and circuit tests reveal no problems, disassemble the heater-A/C housing to inspect for mechanical misalignment or binding of the mode doors. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Heater-A/C Control Assembly Operation > Page 5145 Control Assembly: Testing and Inspection Heater-A/C Control Assembly Vacuum Test 1. Connect the test set vacuum probe to the heater-A/C vacuum supply (black) tube in the engine compartment. Position the test set gauge so that it can be viewed from the passenger compartment. 2. Place the heater-A/C mode control switch knob in each mode position, one position at a time, and pause after each selection. The test set gauge should return to the 27 kPa (8 in. Hg.) setting shortly after each selection is made. If not OK, a component or vacuum line in the vacuum circuit of the selected mode has a leak. CAUTION: Do not use lubricant on the switch ports or in the holes in the plug, as lubricant will ruin the vacuum valve in the switch. A drop of clean water in the connector plug holes will help the connector slide onto the switch ports. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Page 5146 Control Assembly: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 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 Bezel Replacement, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Procedures/Instrument Cluster Bezel Replacement Heater-A/C Control Remove/Install 3. Remove the four screws that secure the heater- A/C control to the instrument panel. 4. Pull the heater-A/C control assembly away from the instrument panel far enough to access the connections on the back of the control. Heater-A/C Control Connections 5. Unplug the wire harness connector from the back of the heater-A/C control. 6. Disconnect the wire harness retainer from the side of the heater-A/C control assembly. 7. Remove the two stamped nuts that secure the vacuum harness connector and unplug the connector from the back of the heater-A/C control. 8. Release the temperature control cable housing flag retainer latch in the receptacle on the back of the heater-A/C control and disengage the flag retainer from the receptacle. 9. Rotate the heater-A/C control assembly to align the cable core with the slot on the end of the temperature control lever and disengage the cable end from the lever. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Page 5147 10. Remove the heater-A/C control from the instrument panel. INSTALLATION 1. Connect the temperature control cable core end to the temperature control lever on the back of the heater-A/C control. 2. Connect the temperature control cable housing flag retainer to the receptacle on the back of the heater-A/C control. 3. Plug in the vacuum harness connector and install the two stamped nuts to secure the connector to the back of the heater-A/C control. 4. Plug the wire harness connector into the back of the heater-A/C control. 5. Reinstall the wire harness retainer to the side of the heater-A/C control. 6. Position the heater-A/C control in the instrument panel and secure it with four screws. Tighten the screws to 2.2 Nm (20 in. lbs.). 7. Reinstall the cluster bezel to the instrument panel. Refer to: Instrument Panel, Gauges and Warning Indicators, Instrument Cluster/Carrier, Service and Repair, Instrument Cluster Bezel Replacement, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Procedures/Instrument Cluster Bezel Replacement 8. Connect the battery negative cable. 9. Adjust the temperature control cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service Precautions Control Module HVAC: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation Coupler HVAC: Description and Operation SYSTEM DESCRIPTION Refrigerant Line Coupler Spring-lock type refrigerant line couplers are used to connect many of the refrigerant lines and other components to the refrigerant system. These couplers require a special tool for disengaging the two coupler halves. 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 blow off protection. In addition, some models have a plastic ring that is used at the factory as a visual indicator to confirm that these couplers are connected. After the coupler is connected, the plastic indicator ring is no longer needed; however, it will remain on the refrigerant line near the coupler cage. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation > Page 5154 Coupler HVAC: Service and Repair WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Recover the refrigerant from the refrigerant system. 2. Remove the secondary clip from the spring-lock coupler. 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. 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 couper 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 springlock couper cage. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5163 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5164 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5165 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5166 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5167 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5168 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5169 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5170 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5171 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5172 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5173 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5174 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-11-99 > Jun > 99 > A/C System - Cooling Performance Deterioration Evaporator Core: Customer Interest A/C System - Cooling Performance Deterioration NUMBER: 24-11-99 GROUP: Heating & A/C DATE: June 25, 1999 SUBJECT: A/C Cooling Performance Deteriorates After A Few Minutes Of Operation OVERVIEW: This bulletin involves adjusting the temperature control cable or installing a new A/C Evaporator MODELS: 1998 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AIR CONDITIONING. SYMPTOM/CONDITION: A/C cooling performance deteriorates after a few minutes of operation. DIAGNOSIS: WARNING: EYE PROTECTION MUST BE WORN WHEN SERVICING THE AIR CONDITIONING REFRIGERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE) ALL VALVES ON THE EQUIPMENT BEING USED BEFORE CONNECTING TO OR DISCONNECTING FROM THE REFRIGERANT SYSTEM. FAILURE TO OBSERVE THESE WARNINGS MAY RESULT IN PERSONAL INJURY. NOTE: THE AIR TEMPERATURE IN THE TEST ROOM AND IN THE VEHICLE MUST BE A MINIMUM OF 21° C. (70° F.) FOR THIS TEST. 1. Connect a tachometer and a manifold gauge set to the vehicle. 2. Set the heater-NC mode control switch knob in the recirculation mode (Max-A/C) position, the temperature control knob in the full cool position, and the blower motor switch knob in the highest speed position. On Durango models with rear NC, set the rear A/C blower control knob to the OFF position. 3. Start the engine and hold the idle at 1000 rpm with the compressor clutch engaged. Refer to the appropriate Service Manual, Group 24, Diagnosis and Testing section if the compressor clutch does not engage. 4. During the test, the engine should be at operating temperature, the doors and windows closed, and the hood mostly closed. 5. Insert a thermometer into the driver side center A/C (panel) outlet. 6. With the compressor clutch engaged, record the panel outlet temperature every 30 seconds for at least five minutes. The temperature should drop at least 20° F. below the ambient temperature within the first 60 seconds of operation. The temperature should continue to drop. After five minutes, the outlet temperature must be at or below those listed in the Performance Temperature and Pressure Chart identified in Group 24 of the appropriate Service Manual. 7. If the suction pressure meets the requirements listed in the Performance Temperature and Pressure Chart identified in Group 24 of the appropriate Service Manual, record the outlet temperature reading. Clamp off both heater hoses (inlet and outlet). Wait five minutes and record the temperature again. Compare the second reading to the list in the Performance Temperature and Pressure Chart. If the temperature is now within the appropriate ranges, the temperature control cable must be adjusted. Refer to the appropriate Service Manual, Group 24, Adjustment section. 8. If the panel outlet temperature began to rise after two - three minutes of operation and eventually levels off at ambient temperature or, the suction pressure drops to 13 psig or less, or the clutch disengages and begins to cycle, perform the Repair Procedure. PARTS REQUIRED: AR (1) 05015440AA Coil, Evaporative, Durango Models Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-11-99 > Jun > 99 > A/C System - Cooling Performance Deterioration > Page 5179 AR (1) 04885579AA Coil, Evaporative, Dakota Models AR 82300101 Refrigerant, R134 EQUIPMENT REQUIRED: R134a Refrigerant/Recycling/Charging Station REPAIR PROCEDURE: 1. Replace the evaporative coil. Refer to the appropriate Service Manual, Group 24, Removal and Installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-50-25-93 Adjust The Temperature Control Cable 1.5 Hrs. 24-65-02-98 Replace The Evaporator Coil 3.8 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5185 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5186 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5187 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5188 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5189 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5190 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5191 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5192 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5193 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5194 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5195 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5196 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-11-99 > Jun > 99 > A/C System - Cooling Performance Deterioration Evaporator Core: All Technical Service Bulletins A/C System - Cooling Performance Deterioration NUMBER: 24-11-99 GROUP: Heating & A/C DATE: June 25, 1999 SUBJECT: A/C Cooling Performance Deteriorates After A Few Minutes Of Operation OVERVIEW: This bulletin involves adjusting the temperature control cable or installing a new A/C Evaporator MODELS: 1998 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AIR CONDITIONING. SYMPTOM/CONDITION: A/C cooling performance deteriorates after a few minutes of operation. DIAGNOSIS: WARNING: EYE PROTECTION MUST BE WORN WHEN SERVICING THE AIR CONDITIONING REFRIGERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE) ALL VALVES ON THE EQUIPMENT BEING USED BEFORE CONNECTING TO OR DISCONNECTING FROM THE REFRIGERANT SYSTEM. FAILURE TO OBSERVE THESE WARNINGS MAY RESULT IN PERSONAL INJURY. NOTE: THE AIR TEMPERATURE IN THE TEST ROOM AND IN THE VEHICLE MUST BE A MINIMUM OF 21° C. (70° F.) FOR THIS TEST. 1. Connect a tachometer and a manifold gauge set to the vehicle. 2. Set the heater-NC mode control switch knob in the recirculation mode (Max-A/C) position, the temperature control knob in the full cool position, and the blower motor switch knob in the highest speed position. On Durango models with rear NC, set the rear A/C blower control knob to the OFF position. 3. Start the engine and hold the idle at 1000 rpm with the compressor clutch engaged. Refer to the appropriate Service Manual, Group 24, Diagnosis and Testing section if the compressor clutch does not engage. 4. During the test, the engine should be at operating temperature, the doors and windows closed, and the hood mostly closed. 5. Insert a thermometer into the driver side center A/C (panel) outlet. 6. With the compressor clutch engaged, record the panel outlet temperature every 30 seconds for at least five minutes. The temperature should drop at least 20° F. below the ambient temperature within the first 60 seconds of operation. The temperature should continue to drop. After five minutes, the outlet temperature must be at or below those listed in the Performance Temperature and Pressure Chart identified in Group 24 of the appropriate Service Manual. 7. If the suction pressure meets the requirements listed in the Performance Temperature and Pressure Chart identified in Group 24 of the appropriate Service Manual, record the outlet temperature reading. Clamp off both heater hoses (inlet and outlet). Wait five minutes and record the temperature again. Compare the second reading to the list in the Performance Temperature and Pressure Chart. If the temperature is now within the appropriate ranges, the temperature control cable must be adjusted. Refer to the appropriate Service Manual, Group 24, Adjustment section. 8. If the panel outlet temperature began to rise after two - three minutes of operation and eventually levels off at ambient temperature or, the suction pressure drops to 13 psig or less, or the clutch disengages and begins to cycle, perform the Repair Procedure. PARTS REQUIRED: AR (1) 05015440AA Coil, Evaporative, Durango Models Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-11-99 > Jun > 99 > A/C System - Cooling Performance Deterioration > Page 5201 AR (1) 04885579AA Coil, Evaporative, Dakota Models AR 82300101 Refrigerant, R134 EQUIPMENT REQUIRED: R134a Refrigerant/Recycling/Charging Station REPAIR PROCEDURE: 1. Replace the evaporative coil. Refer to the appropriate Service Manual, Group 24, Removal and Installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-50-25-93 Adjust The Temperature Control Cable 1.5 Hrs. 24-65-02-98 Replace The Evaporator Coil 3.8 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5202 Evaporator Core: Specifications Rear Overhead A/C Unit Mounting Screws 20 in.lb Upper Housing Cover Mounting Screws 20 in.lb Lower Housing Cover to Rear Overhead A/C Unit Mounting Screws 20 in.lb Rear Overhead A/C Unit Mounting Nuts 100 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5203 Evaporator Core: Locations Evaporator Coil Remove/Install The evaporator coil is located in the heater-A/C housing, under the instrument panel. The rear evaporator coil is located in the rear overhead A/C unit housing, above the headliner. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5204 Evaporator Core: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5205 Evaporator Core: Description and Operation SYSTEM DESCRIPTION Front 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 The evaporator coil is positioned in the overhead 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core Evaporator Core: Service and Repair Front Evaporator Core WARNING: - REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. - ON VEHICLES EQUIPPED WITH AIRBAGS, FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. 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, Heater - A/C Housing Removal and Installation, See: Housing Assembly HVAC/Service and Repair/Heater - A/C Housing Removal and Installation Evaporator Coil Remove/Install 2. 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, Heater - A/C Housing Removal and Installation, See: Housing Assembly HVAC/Service and Repair/Heater - A/C 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core > Page 5208 Evaporator Core: Service and Repair Rear Evaporator Core WARNING: - REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. - ON VEHICLES EQUIPPED WITH AIRBAGS, FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The rear evaporator coil is used only on models with the optional rear overhead A/C unit. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Service and Repair/Refrigerant Recovery 3. Remove the headliner from the passenger compartment of the vehicle. Rear Overhead A/C Unit Refrigerant Line Remove/Install 4. From the passenger compartment remove the nuts that secure the block fittings at the top of the B-pillar refrigerant lines to the studs on the rear overhead A/C unit, and disengage the fittings. Install plugs in, or tape over all of the opened refrigerant line fittings. Rear Overhead A/C Drain Hose Remove/Install 5. Disconnect the B-pillar drain hoses from the way fittings on each side of the rear overhead A/C unit. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core > Page 5209 6. Remove the nine screws that secure the lower housing cover to the rear overhead A/C unit. Rear Overhead A/C Unit Lowe Housing Cover Remove/Install 7. Release the lower housing cover snap retainer near the center of the outlet side (rear) of the rear overhead A/C unit. 8. Feed the rear blower motor switch wire harness and connector through the hole in the right end of the rear overhead A/C unit lower housing cover while removing the cover from the unit. Rear A/C Tube Retaining Strap Remove/Install 9. Remove the screw that secures the rear overhead A/C refrigerant tube and block fitting retaining strap to the right side of the upper housing cover. Rear Evaporator Coil Remove/Install 10. Remove the two screws that secure the rear evaporator coil to the rear overhead A/C unit upper housing cover. 11. Remove the rear evaporator coil from the rear overhead A/C unit. INSTALLATION 1. Position the rear evaporator coil to the rear overhead A/C unit and secure with two mounting screws. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 2. Install the rear overhead A/C refrigerant tube and block fitting retaining strap to the right side of the upper housing cover and secure with a screw. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 3. Feed the rear blower motor switch wire harness and connector through the hole in the right end of the rear overhead A/C unit lower housing cover Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core > Page 5210 while positioning the cover to the unit. 4. Be certain that the lower housing cover snap retainer near the center of the outlet side (rear) of the rear overhead A/C unit is engaged. 5. Install the nine screws that secure the lower housing cover to the rear overhead A/C unit. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 6. Connect the B-pillar drain hoses to the way fittings on each side of the rear overhead A/C unit. 7. Remove the tape or plugs from block fittings at the top of the B-pillar refrigerant line unit, and from the fittings on the rear overhead A/C unit. Install the B-pillar refrigerant line block fittings over the two studs on the rear overhead A/C unit and secure the connections with the mounting nuts. Tighten the mounting nuts to 11.3 Nm (100 in. lbs.). 8. Reinstall the headliner in the passenger compartment of the vehicle. 9. Connect the battery negative cable. 10. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, Evacuating the A/C System, See: Service and Repair/Refrigerant System Evacuate 11. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, A/C System Charge, See: Service and Repair/Refrigerant System Charge NOTE: If the rear evaporator coil and expansion valve unit 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside Technical Service Bulletin # 24-05-99 Date: 990219 Rear A/C Unit - Blows Warm Air When Hot Outside NUMBER: 24-05-99 GROUP: Heater & A/C DATE: Feb. 19, 1999 SUBJECT: Rear A/C Unit Blows Warm Air When Ambient Temperatures Are High OVERVIEW: This bulletin involves installing front and rear expansion valves and in some cases, lowering the headliner and installing front and side/bottom seals to the rear A/C unit. MODELS: 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH REAR A/C (SALES CODE HBA) BUILT BEFORE DECEMBER 14, 1998 (MDH 1214XX). SYMPTOM/CONDITION: The rear A/C unit blows warm air out of the overhead ducts when ambient temperatures are greater than 32°C. (90°F.) with the rear A/C ON and with the front A/C functioning normally. NOTE: THE CONDITION MAY BE WORSE WITH HIGH SUN LOADS APPLIED TO THE ROOF PANEL OF THE VEHICLE. DIAGNOSIS: NOTE: IF THE VEHICLE WAS BUILT BETWEEN OCTOBER 1, 1998 (MDH 1001XX) AND DECEMBER 14, 1998 (MDH 1214XX), PROCEED TO THE EXPANSION THERMAL VALVE REPAIR PROCEDURE. 1. Measure the ambient air temperature of the repair area. DO NOT proceed unless the ambient temperature is at least 21°C (70°F). 2. Connect a tachometer. 3. Set the heater-A/C mode control switch knob to the MAX A/C position. Set the temperature control knob to the full cool position. Set the blower motor switch knob of both the front A/C and rear overhead A/C systems to the high speed position. 4. Start the engine and hold the engine speed at 1,000 rpm with the compressor clutch engaged. Operate the engine until the engine temperature reaches its normal operating range. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside > Page 5219 5. Position a thermometer inside the center inlet of the rear overhead A/C system approximately 19 mm (3/4 in.) ahead of the evaporator and measure the temperature of the air entering the evaporator (Figure 1). NOTE: DO NOT ALLOW THE TEMPERATURE PROBE TO CONTACT THE EVAPORATOR. 6. Position a thermometer approximately 19 mm (3/4 in.) in front of the center in let of the rear overhead A/C system and measure the temperature of the air coming into the rear A/C system through the center inlet (Figure 2). 7. If the temperature of the air directly ahead of the evaporator in the rear overhead A/C system is 20°C. (40°F.) greater than the air in front of the rear overhead A/C system's center inlet, perform the Expansion Thermal Valve Repair Procedure and the Rear A/C Evaporator Seal Repair Procedure. PARTS REQUIRED: 1 55056017AA Seal, Rear A/C Front Foam 1 55056018AA Seal, Rear A/C Side/Bottom Foam AR (1) 55055773AF Valve, Front Thermal Expansion AR (1) 55055876AB Valve, Rear Thermal Expansion AR (1) 55055728AD Label, Refrigerant Charge AR 04886129AA Oil, SP-20 PAG Refrigerant AR 82300101 Refrigerant, R134-A Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside > Page 5220 AR (1) 05015797AA Clip, Electronic Cycling Clutch Switch POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-24-90 Install Rear Overhead A/C Housing Seals 0.9 Hrs. 24-35-20-91 Remove And Install Front And Rear Expansion Valves (Includes Recover And Recharge The A/C System) 0.8 Hrs. FAILURE CODE: P8 - New Part Expansion Thermal Valve 1. Follow the Refrigerant Recovery procedures identified in the 1999 Durango Service Manual (Publication No. 81-370-9116), pages 24-28 and 24-29 and evacuate the A/C system. NOTE: IT IS EXTREMELY IMPORTANT THAT YOU RECLAIM AND WEIGH ANY REFRIGERANT OIL FROM THE REFRIGERANT AFTER IT IS RECOVERED FROM THE A/C SYSTEM. 2. Remove the liquid refrigerant line that is routed between the filter/drier and the front expansion valve. Refer to the 1999 Durango Service Manual (Publication No.81-370-9116), page 24-38 for information regarding Liquid Line - Rear removal procedures. NOTE: ALL REFRIGERANT OIL THAT IS DRAINED FROM THE LIQUID REFRIGERANT LINE MUST BE MEASURED TO ENSURE THAT THE APPROPRIATE AMOUNT OF OIL IS ADDED TO THE SYSTEM AFTER ALL COMPONENTS HAVE BEEN ASSEMBLED. 3. Unplug the wire harness connector from the electronic cycling clutch switch near the expansion valve (Figure 3). 4. Remove and discard the fastener that secures the electronic cycling switch to the outboard side of the expansion valve. 5. Pull the electronic cycling clutch switch away from the expansion valve far enough for the thermistor probe capillary tube to clear the well in the expansion valve. The washer bottle may have to be removed. NOTE: THE CAPILLARY TUBE WELL IN THE EXPANSION VALVE IS FILLED WITH SPECIAL THERMALLY-CONDUCTIVE GREASE. THIS GREASE SHOULD BE REMOVED FROM THE EXPANSION VALVE AND REUSED ON THE NEW EXPANSION VALVE P/N 55055773AF. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside > Page 5221 6. Remove the two screws that secure the expansion valve to the evaporator tube mounting flange (Figure 4). 7. Remove the expansion valve from the evaporator tube mounting flange. NOTE: THE EVAPORATOR TUBE MOUNTING FLANGE SHOULD BE PLUGGED UNTIL THE NEW EXPANSION VALVE IS READY TO BE INSTALLED. 8. Remove the caps, then install the new expansion valve p/n 55055773AF onto the evaporator tube mounting flange and secure with two screws. Tighten the mounting screws to 11.4 N.m (100 in. lbs.). 9. Ensure that the capillary tube well is filled with the thermally-conductive grease removed earlier then, insert the thermistor probe capillary tube of the electronic cycling clutch switch into the well. 10. Install the electronic cycling clutch switch onto the expansion valve and secure it with a new fastener p/n 05015797AA. 11. Plug the wire harness connector into the electronic cycling clutch switch. 12. Remove the underbody refrigerant line. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), page 24-43 for information regarding Underbody Refrigerant Line removal procedures. NOTE: ALL REFRIGERANT OIL THAT IS DRAINED FROM THE UNDERBODY REFRIGERANT LINE OR THE LINES GOING TO THE REAR OVERHEAD A/C EVAPORATOR MUST BE MEASURED TO ENSURE THAT THE APPROPRIATE AMOUNT OF OIL IS ADDED TO THE SYSTEM AFTER ALL COMPONENTS HAVE BEEN ASSEMBLED. 13. Disassemble the bolt from the forward section of the underbody refrigerant line assembly to the expansion valve (Figure 5). Install plugs in or tape over the open refrigerant fittings. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside > Page 5222 14. Disassemble the two bolts attaching the expansion valve to the rearward (shorter) section of the underbody refrigerant lines. NOTE: THE REARWARD SECTION OF THE UNDERBODY REFRIGERANT LINES SHOULD BE PLUGGED UNTIL THE NEW EXPANSION VALVE IS READY TO BE INSTALLED. 15. Remove the caps, then install the new expansion valve p/n 55055876AB onto the rearward section of the underbody refrigerant line mounting flange and secure with two screws. Tighten the mounting screws to 11.4 N.m (100 in. lbs.). 16. Remove the tape or plugs from the forward section of the underbody refrigerant lines. Install new O-rings onto the mounting flange then, align the expansion valve ports and stud with the block fitting on the forward section of the underbody refrigerant lines. secure the lines with the mounting bolt. 17. Install the underbody refrigerant lines. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), page 24-44 for information regarding Underbody Refrigerant Line installation procedures. 18. Install the liquid refrigerant line that is routed between the filter/drier and the front expansion valve. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), page 24-39 for information regarding Liquid Line - Rear installation procedures. 19. Follow the Refrigerant Recovery procedures identified in the 1999 Durango Service Manual (Publication No. 81-370-9116), pages 24-28 and 24-29 and evacuate the A/C system. 20. Weigh all compressor oil that was reclaimed from the A/C refrigerant and/or drained from the A/C components during this repair procedure. Add this amount of new refrigerant oil (SP-20 PAG oil) p/n 04886129AA to the A/C system. NOTE: IF THE RECYCLING STATION IS NOT EQUIPPED WITH A DEVICE TO ADD OIL TO AN EVACUATED SYSTEM, OIL COULD BE ADDED TO THE A/C SYSTEM BY REMOVING THE SUCTION AND DISCHARGE LINES AT THE COMPRESSOR AND INSTALLING THE OIL DIRECTLY INTO THE COMPRESSOR. 21. After the A/C system has been evacuated and tested for leaks, add 32 oz. of R134a refrigerant to the A/C system. A R134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge the A/C system. Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment. 22. Clean all dirt and debris from the A/C underhood label then, install new label p/n 55055728AD over the existing label. 23. Verify proper operation of the A/C system. If necessary, refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), pages 24-13 through 24-16 for information regarding front A/C performance testing and Technical Service Bulletin 24-16-98 for rear A/C performance testing. Rear A/C Evaporator Seal 1. Disconnect the battery negative cable. 2. Using a small flat-bladed screw driver, carefully pry the trim plugs from the A-Pillar grab handle on the passenger side A-Pillar. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside > Page 5223 3. Remove the screws that attach the grab handle to the A-Pillar, then separate the handle from the A-Pillar (Figure 6). 4. Remove the screws from the cowl trim cover, then remove the cowl trim cover. 5. Grasp the A-Pillar trim and pull outward to disengage the clips that attach the A-Pillar trim to the A-Pillar, then separate the trim from the A-Pillar. 6. Remove the screws that attach the sunvisor arm support bracket to the headliner and the roof panel (Figure 7). 7. It equipped, disengage the vanity lamp connector. 8. Detach the sunvisor from the sunvisor supports and separate the sunvisor from the headliner and roof panel. 9. Grasp both sides of the sunvisor support base and firmly pull outward to disengage the sunvisor support cover from the base (Figure 8). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside > Page 5224 NOTE: A TRIM STICK SHOULD BE USED TO DISENGAGE THE SUNVISOR SUPPORT COVER FROM THE BASE. 10. Lift and rock the sunvisor support upward to disengage it from the roof panel. 11. Grasp both sides of the coat hook base and firmly pull outward to disengage the coat hook cover from the base (Figure 9). NOTE: A TRIM STICK SHOULD BE USED TO DISENGAGE THE COAT HOOK COVER FROM THE BASE. 12. Lift and rock the coat hook upward to disengage it from the roof panel (Figure 10). 13. Remove the screws attaching the overhead assist handle to the roof panel and separate it from the roof panel (Figure 11). 14. Perform Steps 4 - 13 to the other side of the vehicle. 15. If the vehicle is equipped with an overhead console, perform Steps 16 through 20. Proceed to Step 21 if the vehicle is not equipped with an overhead console. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside > Page 5225 16. Remove the screw that secures the front of the overhead console to the front of the overhead console bracket (Figure 12). 17. Insert the fingertips of both hands between the headliner and the sides of the overhead console housing in the area between the garage door opener storage bin and the sunglasses storage bin. 18. Pull downward on the sides of the overhead console housing firmly and evenly to disengage the two snap clips that secure the rear of the unit from their receptacles in the overhead console bracket. 19. Lower the overhead console from the headliner far enough to access the wire harness connector and disconnect the connector. 20. Separate the overhead console from the headliner. 21. Remove the front seat belt turning loop cover and turning loop from the driver and passenger side B-Pillars (Figure 13). 22. Grasp the upper B-Pillar trim and pull outward to release the B-Pillar trim. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside > Page 5226 23. Using a trim stick or another suitable wide flat-bladed tool, gently push and pry the release tab located above the two indentations at the outer perimeter of the rear blower motor switch to release it from the headliner (Figure 14). 24. 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, then separate the switch. CAUTION: TO PREVENT DAMAGE TO THE HEADLINER, THE HEADLINER MUST NOT BE ALLOWED TO DROP OR HANG UNSUPPORTED. A WIRE CAN BE FABRICATED TO ACT AS A HANGER TO SUPPORT THE FRONT PORTION OF THE HEADLINER DURING THE NEXT STEPS OF THE REPAIR PROCEDURE. 21. Remove the front seat belt turning loop cover and turning loop from the driver and passenger side B-Pillars (Figure 13). 22. Grasp the upper B-Pillar trim and pull outward to release the B-Pillar trim. 23. Using a trim stick or another suitable wide flat-bladed tool, gently push and pry the release tab located above the two indentations at the outer perimeter of the rear blower motor switch to release it from the headliner (Figure 14). 24. 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, then separate the switch. CAUTION: TO PREVENT DAMAGE TO THE HEADLINER, THE HEADLINER MUST NOT BE ALLOWED TO DROP OR HANG UNSUPPORTED. A WIRE CAN BE FABRICATED TO ACT AS A HANGER TO SUPPORT THE FRONT PORTION OF THE HEADLINER DURING THE NEXT STEPS OF THE REPAIR PROCEDURE. 25. Disengage the outlet bezel from the rear air conditioner by pulling outward on the bezel and prying the bezel loose using a trim stick. 26. Lower the headliner just enough to be able to install the foam seals. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside > Page 5227 27. Clean the surface where the seals will be attached (Figure 15) with isopropyl alcohol. 28. Apply the side/bottom seal by peeling a portion of the adhesive protective strip from the end of the seal p/n 55056018AA. Then, apply the end of the seal to the area shown in Figure 15 and continue by peeling and applying the remainder of the foam seal. NOTE: ON SOME MODELS, A SMALL STRIP OF FOAM TAPE MAY BE PRESENT ON THE BOTTOM OF THE REAR A/C UNIT (FIGURE 15). APPLY THE FOAM TAPE ON TOP OF THE EXISTING FOAM STRIPS IF EQUIPPED. 29. Apply the front seal by peeling a portion of the adhesive protective strip from the end of the seal p/n 55056017AA. Then, apply the end of the seal to the roof bow approximately one inch outside of the position of the side/bottom seal as shown in Figure 15 and continue by peeling and applying the remainder of the foam seal to the roof bow. 30. Push the headliner back into place and install the rear air conditioner outlet bezel. 31. Connect the wire harness connector to the rear blower motor switch. 32. Tuck the wiring harness for the rear blower motor switch back through the rear blower motor switch mounting hole in the headliner. 33. Gently press the rear blower motor switch into the mounting hole in the headliner until the switch snaps into place. 34. Position upper B-Pillar trim onto vehicle and press the trim inward to engage the spring clip retainers. Then, install the B-Pillar trim to the other side of the vehicle. 35. Install the front seat belt turning loop. Tighten the turning loop bolts to 39 N.m (29 ft. lbs.). Then, install the front seat belt turning loop to the other side of the vehicle. 36. Install the turning loop cover. Then, install the turning loop cover to the other side of the vehicle. 37. If the vehicle is equipped with an overhead console, perform Steps 38 through 43. Proceed to Step 44 if the vehicle is not equipped with an overhead console. 38. Position the overhead console near the mounting location on the headliner. 39. Reconnect the roof wire harness connector to the overhead console wire harness connector. 40. Align the locating pin on the rear of the overhead console housing with the receptacle in the rear of the overhead console bracket. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside > Page 5228 41. Align the two snap clips on the overhead console housing with their receptacles in the overhead console bracket. 42. Push upward firmly and evenly on the sides of the overhead console housing over both of the snap clip locations until each of the two snap clips are fully engaged with the receptacle in the overhead console bracket. 43. Install and tighten the screw that secures the front of the overhead console housing to the overhead console bracket. Tighten the screw to 1.9 N.m (17 in. lbs.). 44. Position the overhead assist handle onto the roof panel and secure the handle with the attaching screws. 45. Position the coat hook into the roof panel. 46. Push the coat hook cover inward and secure the coat hook to the roof panel. 47. Position the sunvisor support into the roof panel. 48. Push the sunvisor support cover inward and secure the sunvisor support to the roof panel. 49. Position the sunvisors into the sunvisor supports and align the arm support bracket holes with the headliner holes. 50. Engage the vanity lamp if equipped. 51. Install the screws that attach the sunvisor arm support bracket to the headliner and the roof panel. 52. Position the A-Pillar trim at the A-Pillar, align the spring retaining clips, then press into place. 53. Install the cowl trim cover. 54. Perform Steps 44 - 53 to the other side of the vehicle. 55. On the right side of the vehicle, position the grab handle onto the A-Pillar. 56. Install the screws attaching the grab handle to the A-Pillar. 57. Install the trim plugs into the A-Pillar grab handle. 58. Connect the battery negative cable and reset the clock. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside Technical Service Bulletin # 24-05-99 Date: 990219 Rear A/C Unit - Blows Warm Air When Hot Outside NUMBER: 24-05-99 GROUP: Heater & A/C DATE: Feb. 19, 1999 SUBJECT: Rear A/C Unit Blows Warm Air When Ambient Temperatures Are High OVERVIEW: This bulletin involves installing front and rear expansion valves and in some cases, lowering the headliner and installing front and side/bottom seals to the rear A/C unit. MODELS: 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH REAR A/C (SALES CODE HBA) BUILT BEFORE DECEMBER 14, 1998 (MDH 1214XX). SYMPTOM/CONDITION: The rear A/C unit blows warm air out of the overhead ducts when ambient temperatures are greater than 32°C. (90°F.) with the rear A/C ON and with the front A/C functioning normally. NOTE: THE CONDITION MAY BE WORSE WITH HIGH SUN LOADS APPLIED TO THE ROOF PANEL OF THE VEHICLE. DIAGNOSIS: NOTE: IF THE VEHICLE WAS BUILT BETWEEN OCTOBER 1, 1998 (MDH 1001XX) AND DECEMBER 14, 1998 (MDH 1214XX), PROCEED TO THE EXPANSION THERMAL VALVE REPAIR PROCEDURE. 1. Measure the ambient air temperature of the repair area. DO NOT proceed unless the ambient temperature is at least 21°C (70°F). 2. Connect a tachometer. 3. Set the heater-A/C mode control switch knob to the MAX A/C position. Set the temperature control knob to the full cool position. Set the blower motor switch knob of both the front A/C and rear overhead A/C systems to the high speed position. 4. Start the engine and hold the engine speed at 1,000 rpm with the compressor clutch engaged. Operate the engine until the engine temperature reaches its normal operating range. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside > Page 5234 5. Position a thermometer inside the center inlet of the rear overhead A/C system approximately 19 mm (3/4 in.) ahead of the evaporator and measure the temperature of the air entering the evaporator (Figure 1). NOTE: DO NOT ALLOW THE TEMPERATURE PROBE TO CONTACT THE EVAPORATOR. 6. Position a thermometer approximately 19 mm (3/4 in.) in front of the center in let of the rear overhead A/C system and measure the temperature of the air coming into the rear A/C system through the center inlet (Figure 2). 7. If the temperature of the air directly ahead of the evaporator in the rear overhead A/C system is 20°C. (40°F.) greater than the air in front of the rear overhead A/C system's center inlet, perform the Expansion Thermal Valve Repair Procedure and the Rear A/C Evaporator Seal Repair Procedure. PARTS REQUIRED: 1 55056017AA Seal, Rear A/C Front Foam 1 55056018AA Seal, Rear A/C Side/Bottom Foam AR (1) 55055773AF Valve, Front Thermal Expansion AR (1) 55055876AB Valve, Rear Thermal Expansion AR (1) 55055728AD Label, Refrigerant Charge AR 04886129AA Oil, SP-20 PAG Refrigerant AR 82300101 Refrigerant, R134-A Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside > Page 5235 AR (1) 05015797AA Clip, Electronic Cycling Clutch Switch POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-24-90 Install Rear Overhead A/C Housing Seals 0.9 Hrs. 24-35-20-91 Remove And Install Front And Rear Expansion Valves (Includes Recover And Recharge The A/C System) 0.8 Hrs. FAILURE CODE: P8 - New Part Expansion Thermal Valve 1. Follow the Refrigerant Recovery procedures identified in the 1999 Durango Service Manual (Publication No. 81-370-9116), pages 24-28 and 24-29 and evacuate the A/C system. NOTE: IT IS EXTREMELY IMPORTANT THAT YOU RECLAIM AND WEIGH ANY REFRIGERANT OIL FROM THE REFRIGERANT AFTER IT IS RECOVERED FROM THE A/C SYSTEM. 2. Remove the liquid refrigerant line that is routed between the filter/drier and the front expansion valve. Refer to the 1999 Durango Service Manual (Publication No.81-370-9116), page 24-38 for information regarding Liquid Line - Rear removal procedures. NOTE: ALL REFRIGERANT OIL THAT IS DRAINED FROM THE LIQUID REFRIGERANT LINE MUST BE MEASURED TO ENSURE THAT THE APPROPRIATE AMOUNT OF OIL IS ADDED TO THE SYSTEM AFTER ALL COMPONENTS HAVE BEEN ASSEMBLED. 3. Unplug the wire harness connector from the electronic cycling clutch switch near the expansion valve (Figure 3). 4. Remove and discard the fastener that secures the electronic cycling switch to the outboard side of the expansion valve. 5. Pull the electronic cycling clutch switch away from the expansion valve far enough for the thermistor probe capillary tube to clear the well in the expansion valve. The washer bottle may have to be removed. NOTE: THE CAPILLARY TUBE WELL IN THE EXPANSION VALVE IS FILLED WITH SPECIAL THERMALLY-CONDUCTIVE GREASE. THIS GREASE SHOULD BE REMOVED FROM THE EXPANSION VALVE AND REUSED ON THE NEW EXPANSION VALVE P/N 55055773AF. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside > Page 5236 6. Remove the two screws that secure the expansion valve to the evaporator tube mounting flange (Figure 4). 7. Remove the expansion valve from the evaporator tube mounting flange. NOTE: THE EVAPORATOR TUBE MOUNTING FLANGE SHOULD BE PLUGGED UNTIL THE NEW EXPANSION VALVE IS READY TO BE INSTALLED. 8. Remove the caps, then install the new expansion valve p/n 55055773AF onto the evaporator tube mounting flange and secure with two screws. Tighten the mounting screws to 11.4 N.m (100 in. lbs.). 9. Ensure that the capillary tube well is filled with the thermally-conductive grease removed earlier then, insert the thermistor probe capillary tube of the electronic cycling clutch switch into the well. 10. Install the electronic cycling clutch switch onto the expansion valve and secure it with a new fastener p/n 05015797AA. 11. Plug the wire harness connector into the electronic cycling clutch switch. 12. Remove the underbody refrigerant line. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), page 24-43 for information regarding Underbody Refrigerant Line removal procedures. NOTE: ALL REFRIGERANT OIL THAT IS DRAINED FROM THE UNDERBODY REFRIGERANT LINE OR THE LINES GOING TO THE REAR OVERHEAD A/C EVAPORATOR MUST BE MEASURED TO ENSURE THAT THE APPROPRIATE AMOUNT OF OIL IS ADDED TO THE SYSTEM AFTER ALL COMPONENTS HAVE BEEN ASSEMBLED. 13. Disassemble the bolt from the forward section of the underbody refrigerant line assembly to the expansion valve (Figure 5). Install plugs in or tape over the open refrigerant fittings. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside > Page 5237 14. Disassemble the two bolts attaching the expansion valve to the rearward (shorter) section of the underbody refrigerant lines. NOTE: THE REARWARD SECTION OF THE UNDERBODY REFRIGERANT LINES SHOULD BE PLUGGED UNTIL THE NEW EXPANSION VALVE IS READY TO BE INSTALLED. 15. Remove the caps, then install the new expansion valve p/n 55055876AB onto the rearward section of the underbody refrigerant line mounting flange and secure with two screws. Tighten the mounting screws to 11.4 N.m (100 in. lbs.). 16. Remove the tape or plugs from the forward section of the underbody refrigerant lines. Install new O-rings onto the mounting flange then, align the expansion valve ports and stud with the block fitting on the forward section of the underbody refrigerant lines. secure the lines with the mounting bolt. 17. Install the underbody refrigerant lines. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), page 24-44 for information regarding Underbody Refrigerant Line installation procedures. 18. Install the liquid refrigerant line that is routed between the filter/drier and the front expansion valve. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), page 24-39 for information regarding Liquid Line - Rear installation procedures. 19. Follow the Refrigerant Recovery procedures identified in the 1999 Durango Service Manual (Publication No. 81-370-9116), pages 24-28 and 24-29 and evacuate the A/C system. 20. Weigh all compressor oil that was reclaimed from the A/C refrigerant and/or drained from the A/C components during this repair procedure. Add this amount of new refrigerant oil (SP-20 PAG oil) p/n 04886129AA to the A/C system. NOTE: IF THE RECYCLING STATION IS NOT EQUIPPED WITH A DEVICE TO ADD OIL TO AN EVACUATED SYSTEM, OIL COULD BE ADDED TO THE A/C SYSTEM BY REMOVING THE SUCTION AND DISCHARGE LINES AT THE COMPRESSOR AND INSTALLING THE OIL DIRECTLY INTO THE COMPRESSOR. 21. After the A/C system has been evacuated and tested for leaks, add 32 oz. of R134a refrigerant to the A/C system. A R134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge the A/C system. Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment. 22. Clean all dirt and debris from the A/C underhood label then, install new label p/n 55055728AD over the existing label. 23. Verify proper operation of the A/C system. If necessary, refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), pages 24-13 through 24-16 for information regarding front A/C performance testing and Technical Service Bulletin 24-16-98 for rear A/C performance testing. Rear A/C Evaporator Seal 1. Disconnect the battery negative cable. 2. Using a small flat-bladed screw driver, carefully pry the trim plugs from the A-Pillar grab handle on the passenger side A-Pillar. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside > Page 5238 3. Remove the screws that attach the grab handle to the A-Pillar, then separate the handle from the A-Pillar (Figure 6). 4. Remove the screws from the cowl trim cover, then remove the cowl trim cover. 5. Grasp the A-Pillar trim and pull outward to disengage the clips that attach the A-Pillar trim to the A-Pillar, then separate the trim from the A-Pillar. 6. Remove the screws that attach the sunvisor arm support bracket to the headliner and the roof panel (Figure 7). 7. It equipped, disengage the vanity lamp connector. 8. Detach the sunvisor from the sunvisor supports and separate the sunvisor from the headliner and roof panel. 9. Grasp both sides of the sunvisor support base and firmly pull outward to disengage the sunvisor support cover from the base (Figure 8). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside > Page 5239 NOTE: A TRIM STICK SHOULD BE USED TO DISENGAGE THE SUNVISOR SUPPORT COVER FROM THE BASE. 10. Lift and rock the sunvisor support upward to disengage it from the roof panel. 11. Grasp both sides of the coat hook base and firmly pull outward to disengage the coat hook cover from the base (Figure 9). NOTE: A TRIM STICK SHOULD BE USED TO DISENGAGE THE COAT HOOK COVER FROM THE BASE. 12. Lift and rock the coat hook upward to disengage it from the roof panel (Figure 10). 13. Remove the screws attaching the overhead assist handle to the roof panel and separate it from the roof panel (Figure 11). 14. Perform Steps 4 - 13 to the other side of the vehicle. 15. If the vehicle is equipped with an overhead console, perform Steps 16 through 20. Proceed to Step 21 if the vehicle is not equipped with an overhead console. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside > Page 5240 16. Remove the screw that secures the front of the overhead console to the front of the overhead console bracket (Figure 12). 17. Insert the fingertips of both hands between the headliner and the sides of the overhead console housing in the area between the garage door opener storage bin and the sunglasses storage bin. 18. Pull downward on the sides of the overhead console housing firmly and evenly to disengage the two snap clips that secure the rear of the unit from their receptacles in the overhead console bracket. 19. Lower the overhead console from the headliner far enough to access the wire harness connector and disconnect the connector. 20. Separate the overhead console from the headliner. 21. Remove the front seat belt turning loop cover and turning loop from the driver and passenger side B-Pillars (Figure 13). 22. Grasp the upper B-Pillar trim and pull outward to release the B-Pillar trim. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside > Page 5241 23. Using a trim stick or another suitable wide flat-bladed tool, gently push and pry the release tab located above the two indentations at the outer perimeter of the rear blower motor switch to release it from the headliner (Figure 14). 24. 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, then separate the switch. CAUTION: TO PREVENT DAMAGE TO THE HEADLINER, THE HEADLINER MUST NOT BE ALLOWED TO DROP OR HANG UNSUPPORTED. A WIRE CAN BE FABRICATED TO ACT AS A HANGER TO SUPPORT THE FRONT PORTION OF THE HEADLINER DURING THE NEXT STEPS OF THE REPAIR PROCEDURE. 21. Remove the front seat belt turning loop cover and turning loop from the driver and passenger side B-Pillars (Figure 13). 22. Grasp the upper B-Pillar trim and pull outward to release the B-Pillar trim. 23. Using a trim stick or another suitable wide flat-bladed tool, gently push and pry the release tab located above the two indentations at the outer perimeter of the rear blower motor switch to release it from the headliner (Figure 14). 24. 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, then separate the switch. CAUTION: TO PREVENT DAMAGE TO THE HEADLINER, THE HEADLINER MUST NOT BE ALLOWED TO DROP OR HANG UNSUPPORTED. A WIRE CAN BE FABRICATED TO ACT AS A HANGER TO SUPPORT THE FRONT PORTION OF THE HEADLINER DURING THE NEXT STEPS OF THE REPAIR PROCEDURE. 25. Disengage the outlet bezel from the rear air conditioner by pulling outward on the bezel and prying the bezel loose using a trim stick. 26. Lower the headliner just enough to be able to install the foam seals. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside > Page 5242 27. Clean the surface where the seals will be attached (Figure 15) with isopropyl alcohol. 28. Apply the side/bottom seal by peeling a portion of the adhesive protective strip from the end of the seal p/n 55056018AA. Then, apply the end of the seal to the area shown in Figure 15 and continue by peeling and applying the remainder of the foam seal. NOTE: ON SOME MODELS, A SMALL STRIP OF FOAM TAPE MAY BE PRESENT ON THE BOTTOM OF THE REAR A/C UNIT (FIGURE 15). APPLY THE FOAM TAPE ON TOP OF THE EXISTING FOAM STRIPS IF EQUIPPED. 29. Apply the front seal by peeling a portion of the adhesive protective strip from the end of the seal p/n 55056017AA. Then, apply the end of the seal to the roof bow approximately one inch outside of the position of the side/bottom seal as shown in Figure 15 and continue by peeling and applying the remainder of the foam seal to the roof bow. 30. Push the headliner back into place and install the rear air conditioner outlet bezel. 31. Connect the wire harness connector to the rear blower motor switch. 32. Tuck the wiring harness for the rear blower motor switch back through the rear blower motor switch mounting hole in the headliner. 33. Gently press the rear blower motor switch into the mounting hole in the headliner until the switch snaps into place. 34. Position upper B-Pillar trim onto vehicle and press the trim inward to engage the spring clip retainers. Then, install the B-Pillar trim to the other side of the vehicle. 35. Install the front seat belt turning loop. Tighten the turning loop bolts to 39 N.m (29 ft. lbs.). Then, install the front seat belt turning loop to the other side of the vehicle. 36. Install the turning loop cover. Then, install the turning loop cover to the other side of the vehicle. 37. If the vehicle is equipped with an overhead console, perform Steps 38 through 43. Proceed to Step 44 if the vehicle is not equipped with an overhead console. 38. Position the overhead console near the mounting location on the headliner. 39. Reconnect the roof wire harness connector to the overhead console wire harness connector. 40. Align the locating pin on the rear of the overhead console housing with the receptacle in the rear of the overhead console bracket. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 24-05-99 > Feb > 99 > Rear A/C Unit - Blows Warm Air When Hot Outside > Page 5243 41. Align the two snap clips on the overhead console housing with their receptacles in the overhead console bracket. 42. Push upward firmly and evenly on the sides of the overhead console housing over both of the snap clip locations until each of the two snap clips are fully engaged with the receptacle in the overhead console bracket. 43. Install and tighten the screw that secures the front of the overhead console housing to the overhead console bracket. Tighten the screw to 1.9 N.m (17 in. lbs.). 44. Position the overhead assist handle onto the roof panel and secure the handle with the attaching screws. 45. Position the coat hook into the roof panel. 46. Push the coat hook cover inward and secure the coat hook to the roof panel. 47. Position the sunvisor support into the roof panel. 48. Push the sunvisor support cover inward and secure the sunvisor support to the roof panel. 49. Position the sunvisors into the sunvisor supports and align the arm support bracket holes with the headliner holes. 50. Engage the vanity lamp if equipped. 51. Install the screws that attach the sunvisor arm support bracket to the headliner and the roof panel. 52. Position the A-Pillar trim at the A-Pillar, align the spring retaining clips, then press into place. 53. Install the cowl trim cover. 54. Perform Steps 44 - 53 to the other side of the vehicle. 55. On the right side of the vehicle, position the grab handle onto the A-Pillar. 56. Install the screws attaching the grab handle to the A-Pillar. 57. Install the trim plugs into the A-Pillar grab handle. 58. Connect the battery negative cable and reset the clock. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 5244 Expansion Valve: Specifications Expansion Valve Mounting Screws 100 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 5245 Expansion Valve: Locations Expansion Valve Remove/Install 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 Vehicles equipped with the optional rear overhead A/C unit have an H-type thermal expansion valve (TXV) located underneath the passenger side of the vehicle floor panel, next to the sill. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 5246 Expansion Valve: Service Precautions WARNING: EXTREME CARE MUST BE USED WHEN HANDLING LIQUID CARBON DIOXIDE (CO2), AS SKIN INJURY CAN OCCUR. PROTECTIVE GLOVES SHOULD BE WORN . Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 5247 Expansion Valve: Description and Operation SYSTEM DESCRIPTION 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. A temperature sensor in the expansion valve control head monitors the temperature 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 Vehicles equipped with the optional rear overhead A/C unit have an H-type thermal expansion valve (TXV) located underneath the passenger side of the vehicle floor panel, next to the sill. It performs the same function as the front expansion valve, to monitor refrigerant temperature 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 5248 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. 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 (CO2), AS SKIN INJURY CAN OCCUR. PROTECTIVE GLOVES SHOULD BE WORN. 3. Apply liquid carbon dioxide (CO2) 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 (CO2) 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 207 kPa (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. 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. WARNING: EXTREME CARE MUST BE USED WHEN HANDLING LIQUID CARBON DIOXIDE (CO2) 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 (CO2) 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 (CO2) 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 (CO2) 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 5249 Expansion Valve: Service and Repair FRONT WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Remove the rear liquid line from the engine compartment. 4. Remove the electronic cycling clutch switch from the outboard side of the expansion valve. Expansion Valve Remove/Install 5. Remove the two screws that secure the expansion valve to the evaporator tube mounting flange. 6. 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. Remove the tape or plugs from the evaporator tubes and the evaporator tube mounting flange side of the expansion valve. Install the expansion valve to the evaporator tube mounting flange and secure with two screws. Tighten the mounting screws to 11.4 Nm (100 in. lbs.). 2. Reinstall the electronic cycling clutch switch to the outboard side of the expansion valve. 3. Reinstall the rear liquid line to the engine compartment. 4. Connect the battery negative cable. 5. Evacuate the refrigerant system. 6. Charge the refrigerant system. REAR WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 5250 Rear Expansion Valve Removal/Install 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Remove the engine air filter housing. 4. Remove the underbody line. Remove the line from the vehicle and install plugs in, or tape over, all of the open refrigerant fittings. 5. Disassemble the bolt (M6) from the forward (longer) section of the underbody lines to the valve. install plugs in, or tape over the open refrigerant fittings. 6. Disassemble the two bolts attaching the expansion valve to the rearward (shorter) section of the underbody lines. install plugs in, or tape over the open refrigerant fittings. INSTALLATION 1. Remove the tape or plugs from expansion valve and the rearward (shorter) section of the underbody lines. Align the expansion valve ports with the block fitting on the rearward lines and assemble with the two bolts. 2. Remove the tape or plugs from the forward (longer) section of the underbody lines. Align the expansion valve ports and stud with the block fitting on the forward lines. Secure with the mounting bolt. 3. Install the underbody refrigerant lines. 4. Install the engine air filter housing. 5. Evacuate and charge the refrigerant system. 6. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations Heater Core: Locations The heater core is located in the heater-A/C housing, under the instrument panel. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations > Page 5254 Heater Core: Description and Operation SYSTEM DESCRIPTION It is a heat exchanger made of rows of tubes and fins. 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 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations > Page 5255 Heater Core: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. 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, Heater - A/C Housing Removal and Installation, See: Housing Assembly HVAC/Service and Repair/Heater - A/C Housing Removal and Installation Heater Core Remove/Install 2. 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 and reinstall the heater-A/C housing in the vehicle. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Heater - A/C Housing Removal and Installation, See: Housing Assembly HVAC/Service and Repair/Heater - A/C Housing Removal and Installation Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications High Pressure Safety Valve HVAC: Specifications 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 when a minimum discharge pressure of 2756 kPa (400 psi) is reached. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Page 5259 High Pressure Safety Valve HVAC: Locations A high pressure relief valve is located on the compressor cylinder head, which is at the rear of the compressor. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Page 5260 High Pressure Safety Valve HVAC: Description and Operation SYSTEM OPERATION High Pressure Relief Valve 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > A/C Discharge Hose/Line Hose/Line HVAC: Specifications Refrigerant Line Mounting Screws 20 in.lb B-Pillar Refrigerant Line Mounting Nuts 100 in.lb B-Pillar Refrigerant Line Clamp Mounting Screws 20 in.lb B-Pillar Refrigerant Line Mounting Screw 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > A/C Discharge Hose/Line > Page 5265 Hose/Line HVAC: Specifications Front Liquid Line Block Fitting to Filter-Drier Inlet Mounting Screw 120 in.lb Rear Liquid Line Block Fitting to Expansion Valve Stud Mounting Nut 200 in.lb Rear Liquid Line Block Fitting to Filter-Drier Outlet Mounting Screw 120 in.lb Ground Strap to Inboard Side of Rear Liquid Line Block Mounting Screw 60 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > A/C Discharge Hose/Line > Page 5266 Hose/Line HVAC: Specifications Refrigerant Line Manifold Mounting Screw 200 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Locations > A/C Discharge Hose/Line Suction And Discharge Line Remove/Install - Typical Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Locations > A/C Discharge Hose/Line > Page 5269 B-Pillar Refrigerant Lines Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Locations > A/C Discharge Hose/Line > Page 5270 Suction And Discharge Line Remove/Install - Typical Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Locations > Page 5271 Hose/Line HVAC: Description and Operation SYSTEM DESCRIPTION Refrigerant Line 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 inner hose liner is used for the R-134a air conditioning system on this vehicle. This nylon liner 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 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 status 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. Low Pressure Gauge Hose The low pressure hose (Blue with Black stripe) attaches to the suction service port. This port is located on the compressor manifold, directly over the suction port of the compressor. High Pressure Gauge Hose The high pressure hose (Red with Black stripe) attaches to the discharge service port. This port is located on the liquid line between the condenser and the evaporator, near the front of the engine compartment. Recovery/Recycling/Evacuation/Charging Hose The center manifold hose (Yellow, or White, with Black stripe) is used to recover, evacuate, and charge the refrigerant system. When the low or high pressure valves on the manifold gauge set are opened, the refrigerant in the system will escape through this hose. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 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. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Service and Repair/Refrigerant Recovery 3. Unplug the wire harness connector from the high pressure cut-off switch. 4. Disconnect the refrigerant line couplers at the condenser and the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the nut that secures the refrigerant line support bracket near the compressor. Suction And Discharge Line Remove/Install - Typical 6. 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. 7. Remove the suction and discharge line assembly from the vehicle. INSTALLATION 1. Remove the tape or plugs from all of the refrigerant line fittings. Install the refrigerant line couplers to the condenser and the suction line jumper. 2. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 Nm (200 in. lbs.). 3. Install the nut that secures the refrigerant line support bracket near the compressor. 4. Plug in the wire harness connector to the high pressure cut-off switch. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, Evacuating the A/C System, See: Service and Repair/Refrigerant System Evacuate 7. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, A/C System Charge, See: Service and Repair/Refrigerant System Charge Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5274 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement 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. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. FRONT REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Service and Repair/Refrigerant Recovery Liquid Line Remove/Install 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. INSTALLATION 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. Connect the battery negative cable. 4. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, Evacuating the A/C System, See: Service and Repair/Refrigerant System Evacuate 5. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, A/C System Charge, See: Service and Repair/Refrigerant System Charge REAR REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Service and Repair/Refrigerant Recovery Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5275 3. Remove the engine air filter housing. 4. Remove the nut that secures the ground strap to the inboard side of the rear liquid line block fitting. 5. Remove the screw that secures the rear liquid line block fitting to the outlet 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. 6. Disconnect the suction line from the suction jumper. 7. If the vehicle is equipped with the optional rear overhead A/C unit, disconnect the refrigerant line couplers near the dash panel between the suction line jumper and the rear liquid line extension and both of the underbody refrigerant lines. Install plugs in, or tape over all of the opened refrigerant line fittings. 8. Disengage the clip that secures the rear liquid line to the inner fender shield. 9. Remove the nut that secures the rear liquid line block fitting to the stud on the expansion valve, and disengage the fitting from the expansion valve. Install plugs in, or tape over all of the opened refrigerant line fittings. 10. Remove the rear liquid line from the engine compartment. 11. Remove the suction line jumper from the rear liquid line block fitting. INSTALLATION 1. Install the suction line jumper into the rear liquid line block fitting. 2. Remove the tape or plugs from the rear liquid line block fitting and the expansion valve. Install the rear liquid line block fitting over the expansion valve stud and secure the connection with a nut. Tighten the mounting nut to 22.5 Nm (200 in. lbs.). 3. Install the rear liquid line in the clip on the inner fender shield. 4. If the vehicle is equipped with the optional rear overhead A/C unit, remove the tape or plugs from the refrigerant line fittings on the suction line jumper and the rear liquid line extension and both of the underbody refrigerant lines. Connect the underbody refrigerant lines to the suction line jumper and the rear liquid line extension. 5. 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.). Connect the suction line from the suction discharge assembly to the suction jumper tube. 6. Reinstall the nut that secures the ground strap to the inboard side of the rear liquid line block fitting. Tighten the mounting screw to 6.8 Nm (60 in. lbs.). 7. Reinstall the engine air filter housing. 8. Connect the battery negative cable. 9. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, Evacuating the A/C System, See: Service and Repair/Refrigerant System Evacuate 10. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, A/C System Charge, See: Service and Repair/Refrigerant System Charge Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5276 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement Suction and Discharge 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. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Service and Repair/Refrigerant Recovery 3. Unplug the wire harness connector from the high pressure cut-off switch. 4. Disconnect the refrigerant line couplers at the condenser and the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the nut that secures the refrigerant line support bracket near the compressor. Suction And Discharge Line Remove/Install - Typical 6. 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. 7. Remove the suction and discharge line assembly from the vehicle. INSTALLATION 1. Remove the tape or plugs from all of the refrigerant line fittings. Install the refrigerant line couplers to the condenser and the suction line jumper. 2. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 Nm (200 in. lbs.). 3. Install the nut that secures the refrigerant line support bracket near the compressor. 4. Plug in the wire harness connector to the high pressure cut-off switch. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, Evacuating the A/C System, See: Service and Repair/Refrigerant System Evacuate 7. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, A/C System Charge, See: Service and Repair/Refrigerant System Charge Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5277 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. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 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, Service and Repair, Refrigerant Recovery, See: 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 rear 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 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, Service and Repair, Refrigerant System Evacuate, Evacuating the A/C System, See: Service and Repair/Refrigerant System Evacuate 8. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, A/C System Charge, See: Service and Repair/Refrigerant System Charge Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5278 Hose/Line HVAC: Service and Repair B-Pillar Refrigerant Line Replacement The B-pillar refrigerant lines are used only on models with the optional rear overhead A/C unit. Both the B-pillar suction line and the B-pillar liquid line are available for separate service replacement. Each line may be removed independently from the vehicle for service. 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. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Service and Repair/Refrigerant Recovery 3. Raise and support the vehicle. 4. From under the vehicle, disconnect the underbody liquid line refrigerant line coupler at the B-pillar liquid line and the underbody suction line refrigerant line coupler at the B-pillar suction line. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Lower the vehicle. 6. Remove the headliner from the passenger compartment of the vehicle. Rear Overhead A/C Unit Refrigerant Line Remove/Install 7. From the passenger compartment, remove the fasteners that secure the block fittings at the top of the B-pillar refrigerant lines to the rear overhead A/C unit (nut from stud - liquid line) (nut and bolt suction line), and disengage the fittings. Install plugs in, or tape over all of the opened refrigerant line fittings. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5279 B-Pillar Refrigerant Lines Remove/Install 8. Remove the two screws that secure the B-pillar refrigerant line clamps to the B-pillar. 9. Remove the two screws that secure the B-pillar refrigerant line clamp and seal unit to the floor panel at the base of the B-pillar. 10. Tilt the top of the B-pillar refrigerant line unit towards the front of the vehicle far enough so that the tower end of the unit can be lifted out through the hole in the floor panel. 11. Remove the B-pillar refrigerant line unit from the passenger compartment. NOTE: If either the liquid line or the suction line is removed from the B-pillar refrigerant line clamp and seal, the clamp and seal will be damaged. Replace the clamp and seal with a new unit. INSTALLATION 1. Position the B-pillar refrigerant line unit in the passenger compartment with the lower end of the lines inserted through the hole in the floor panel at the base of the B-pillar, and the top end of the lines oriented towards the front of the vehicle. 2. Tilt the top of the B-pillar refrigerant line unit up into position near the rear overhead A/C unit. 3. Remove the tape or plugs from block fittings at the top of the B-pillar refrigerant line unit, and from the fittings on the rear overhead A/C unit. Install the B-pillar refrigerant line block fittings over the one stud on the rear overhead A/C unit. Install the bolt holding the suction line, and secure the connections with the mounting nuts. Tighten the mounting nuts to 11.3 Nm (100 in. lbs.). 4. Position the B-pillar refrigerant line clamp and seal over the hole in the floor panel and secure it with two screws. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 5. Position the B-pillar refrigerant line over the mounting holes in the inner B-pillar and secure with a screw. Tighten the mounting screw to 2.2 Nm (20 in. lbs.). 6. Reinstall the headliner in the passenger compartment. 7. Raise and support the vehicle. 8. From under the vehicle, remove the tape or plugs from the refrigerant line fittings at the underbody and B-pillar liquid lines, and from the underbody and B-pillar suction lines. Connect the underbody refrigerant lines to the B-pillar refrigerant lines. 9. Connect the battery negative cable. 10. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair. Refrigerant System Evacuate, Evacuating the A/C System, See: Service and Repair/Refrigerant System Evacuate 11. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, A/C System Charge, See: Service and Repair/Refrigerant System Charge Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5280 Hose/Line HVAC: Service and Repair Underbody Refrigerant Line Replacement The underbody refrigerant lines are used only on models with the optional rear overhead A/C unit. Both the underbody suction line and the underbody liquid line are available for separate service replacement, and may be removed from the vehicle independently for service. 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. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Service and Repair/Refrigerant Recovery Underbody Refrigerant Line Remove/Install 3. From the engine compartment, disconnect the underbody liquid line refrigerant line coupler at the liquid line extension and the underbody suction line refrigerant line coupler at the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Raise and support the vehicle. 5. From under the vehicle, disconnect the underbody liquid line refrigerant line coupler at the B-pillar liquid line and the underbody suction line refrigerant line coupler at the B-pillar suction line. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Remove the screws that secure the three underbody refrigerant line clamps to the underbody. 7. Remove the underbody refrigerant line unit from the vehicle. INSTALLATION 1. From under the vehicle, position the underbody refrigerant line unit to the underbody and secure the refrigerant line clamps with the mounting screws in three places. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 2. Remove the tape or plugs from the refrigerant line fittings at the rear of the underbody liquid and suction lines and at the B-pillar liquid and suction lines. Connect the underbody refrigerant lines to the B-pillar refrigerant lines. 3. Lower the vehicle. 4. From the engine compartment, remove the tape or plugs from the refrigerant line fittings at the front of the underbody liquid and suction lines and at the liquid line extension and the suction line jumper. Connect the underbody refrigerant lines to the engine compartment refrigerant lines. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, Evacuating the A/C System, See: Service and Repair/Refrigerant System Evacuate 7. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, A/C System Charge, See: Service and Repair/Refrigerant System Charge Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Specifications Housing Assembly HVAC: Specifications Blower Motor Screws 20 in.lb Heater-A/C Housing 20 in.lb Bottom Heater-A/C Housing Screws 20 in.lb Heater-A/C Housing Cover to Top of Blower Motor Housing Cover Screws 20 in.lb Heater-A/C Housing Mounting Brace to Dash Panel Stud Nut 95 in.lb Passenger Compartment Side Heater-A/C Housing Mounting Stud Nuts 60 in.lb Engine Compartment Side Overhead A/C Unit Mounting Screws 105 in.lb Suction Line Connection Mounting Nuts Retaining Bolt 100 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Specifications > Page 5284 Housing Assembly HVAC: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR a SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly Housing Assembly HVAC: Service and Repair Heater-A/C Housing Disassembly and Assembly 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: ON VEHICLES EQUIPPED WITH AIR-BAGS, FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Disassembly 1. Place the heater-A/C housing on a work bench, with the heater-A/C housing cover facing down. 2. Remove the two screws that secure the heater- A/C housing cover to the top of the blower motor housing cover. 3. If the vehicle is so equipped, unplug the two vacuum harness connectors from the recirculation air door actuator. 4. Unplug the vacuum harness connector from the panel-defrost door actuator. 5. Remove the four screws that secure the floor duct to the bottom of the heater-A/C housing and remove the duct from the housing. Heater-A/C Housing Floor Outlet Screws 6. Remove the two screws that secure the heater- A/C housing cover to the lower housing near the floor outlet. 7. Turn the heater-A/C housing over on the work bench, with the heater-A/C housing cover facing up. 8. Disengage the vacuum harness retainer from the hole near the left end of the heater-A/C housing cover. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5287 Blend-Air Door Lever Remove/Install 9. Remove the vacuum harness from the molded clips on the heater-A/C housing cover. 10. Remove the thirteen screws that secure the pen meter of the housing cover to the heater-A/C housing. 11. Remove the nut that secures the blend-air door lever to the blend-air door pivot shaft and remove the lever. 12. Gently pry off the push nut that secures the heater-A/C housing cover to the heater-A/C housing post. Panel-Defrost Door Lever Remove 13. Using a trim stick or another suitable wide flat-bladed tool, gently pry the panel-defrost door lever off of the panel-defrost door pivot shaft. 14. Pull up the perimeter edges of the heater-A/C housing cover far enough to separate the cover sealant from the heater-A/C housing. 15. Remove the housing cover from the heater A/C housing. 16. If the vehicle is so equipped, remove the recirculation air door actuator from the blower motor housing cover. Blower Motor Housing Cover Remove/Install 17. Remove the six screws that secure the blower motor housing cover to the heater-A/C housing. 18. Remove the blower motor housing cover from the heater-A/C housing. Assembly Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5288 Blower Motor Housing Cover Sealant 1. Before installing the blower motor housing cover, be certain that the cover sealant is in place and in good condition. 2. Position the blower motor housing cover to the heater-A/C housing. 3. Install the six screws that secure the blower motor housing cover to the heater-A/C housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 4. If the vehicle is so equipped, reinstall the recirculation air door actuator. Heater A/C Housing Cover Sealant 5. Before installing the heater-A/C housing cover, be certain that the cover sealant is in place and in good condition. 6. Position the heater-A/C housing cover on the heater-A/C housing. Be certain that the pivots for the floor-defrost, the panel-defrost, the blend-air, and the recirculation air (if the vehicle is so equipped) doors are properly positioned. 7. Reinstall the push nut that secures the heater- A/C housing cover to the heater-A/C housing post. 8. Install the thirteen screws that secure the perimeter of the housing cover to the heater-A/C housing. Tighten the screws to 2.2 Nm (20 in.lbs.). 9. Snap the panel-defrost door lever onto the panel-defrost door pivot shaft. 10. Install the blend-air door lever to the blend air door pivot shaft and secure it to the shaft with the nut. 11. Install the vacuum harness retainer into the hole near the left end of the heater-A/C housing cover. 12. Route the vacuum harness through the molded clips on the heater-A/C housing cover. 13. Turn the heater-A/C housing over on the work bench, with the heater-A/C housing cover facing down. 14. Install the two screws that secure the heater- A/C housing cover to the lower housing near the floor outlet. Tighten the screws to 2.2 Nm (20 in. lbs.). 15. Position the floor duct to the bottom of the heater-A/C housing and secure with four screws. Tighten the screws to 2.2 Nm (20 in. lbs.). 16. Plug in the vacuum harness connector to the panel-defrost door actuator. 17. If the vehicle is so equipped, plug in the two vacuum harness connectors to the recirculation air door actuator. 18. Install the two screws that secure the heaterA/C housing cover to the top of the blower motor housing cover. Tighten the screws to 2.2 Nm (20 in. lbs.). 19. Reinstall the heater-A/C housing in the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5289 Housing Assembly HVAC: Service and Repair Heater-A/C Housing Door Removal and Installation WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Blend-Air Door 1. Remove the heater-A/C housing from the vehicle, and remove the housing cover. Blend-Air Door Remove/Install 2. Lift the blend-air door pivot shaft out of the pivot hole in the bottom of the heater-A/C housing. 3. Reverse the removal procedures to install. Floor-Defrost Door 1. Remove the heater-A/C housing from the vehicle, and remove the housing cover. Refer to Heater-A/C Housing Replacement for the procedures. Floor-Defrost Door Remove/Install 2. Remove the push nut retainer that secures the floor-defrost door actuator link to the floor-defrost door crank arm. 3. Disengage the floor-defrost door actuator link from the floor-defrost door crank arm. 4. Remove the floor-defrost door from the heater A/C housing. 5. Reverse the removal procedures to install. Panel-Defrost Door 1. Remove the heater-A/C housing from the vehicle, and remove the housing cover. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5290 Panel-Defrost Door Remove/Install 2. Lift the panel-defrost door out of the heater-A/C housing. Assure that the chute assembly on the panel-defrost door is properly positioned. 3. Reverse the removal procedures to install. Recirculation Air Door A recirculation air door and vacuum actuator are used only on models with the optional air conditioning system. 1. Remove the heater-A/C housing from the vehicle, and remove the housing cover. 2. Remove the recirculation air door actuator from the blower motor housing cover. Refer to: "Air Door Actuator-Motor, HVAC : Service and Repair" See: Air Door/Air Door Actuator / Motor/Service and Repair Recirculation Air Door Remove/Install 3. Lift the lower end of the recirculation air door up far enough so that the door lever is clear of the recirculation air intake grille, then twist the door to remove the door pivots from the pivot holes in the blower motor housing cover. 4. Remove the recirculation air door from the blower motor housing cover. 5. Reverse the removal procedures to install. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5291 Housing Assembly HVAC: Service and Repair Heater - A/C Housing Removal and Installation 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: ON VEHICLES EQUIPPED WITH AIR-BAGS, FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 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 Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Procedures/Instrument Panel Assembly Replacement 3. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: 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. Refer to: Heating and Air Conditioning, Expansion valve, Service and Repair, Expansion Valve Removal and Installation, See: Expansion Valve/Service and Repair 5. Drain the engine cooling system. 6. Disconnect the heater hoses from the heater core tubes. Heater-A/C Housing Remove/Install 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 nut that secures the heater-A/C housing mounting brace to the stud on the passenger compartment side of the dash panel. 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. INSTALLATION 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 nut that secures the heater-A/C housing mounting brace to the stud on the passenger compartment side of the dash panel. Tighten the nut to 11 Nm (95 in. lbs.). 3. Engage the front floor panel transmission tunnel duct with the adapter on the heater-A/C housing. 4. 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5292 7 Nm (60 in. lbs.). 5. 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. 6. Reinstall the front expansion valve to the evaporator tube mounting flange. Refer to: Heating and Air Conditioning, Expansion valve, Service and Repair, Expansion Valve Removal and Installation, See: Expansion Valve/Service and Repair 7. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, Evacuating the A/C System, See: Service and Repair/Refrigerant System Evacuate 8. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, A/C System Charge, See: Service and Repair/Refrigerant System Charge 9. Reinstall the instrument panel in the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Procedures/Instrument Panel Assembly Replacement 10. Connect the battery negative cable. 11. Start the engine and check for proper operation of the heating and air conditioning systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5293 Housing Assembly HVAC: Service and Repair Rear Heater-A/C Unit Replacement and Service REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Service and Repair/Refrigerant Recovery 3. Remove the headliner from the passenger compartment of the vehicle. Rear Overhead A/C Unit Refrigerant Line Remove/Install 4. From the passenger compartment, remove the nut from the bolt, (suction line) and nut from stud, (liquid line) that secure the block fittings at the top of the B-pillar refrigerant lines on the rear overhead A/C unit, and disengage the fittings. Install plugs in, or tape over all of the opened refrigerant line fittings. Rear Overhead A/C Drain Hose Remove/Install 5. Disconnect the B-pillar drain hoses from the way fittings on each side of the rear overhead A/C unit. 6. Unplug the rear overhead A/C unit wire harness connector located at the left side of the unit. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5294 Rear Overhead A/C Unit Remove/Install 7. Loosen but do not remove the two screws that secure the mounting bracket on the left end of the rear overhead A/C unit to the left roof rail. 8. Support the right end of the rear overhead A/C unit while removing the two screws that secure the mounting bracket on the right end of the unit to the right roof rail. 9. Slide the rear overhead A/C unit towards the right side of the vehicle far enough to disengage the slotted holes on the left end of the mounting bracket from the loosened screws in the left roof rail. 10. Remove the rear overhead A/C unit from the passenger compartment. INSTALLATION 1. Engage the slotted holes in the left end of rear overhead A/C unit mounting bracket with the loosened screws in the left roof rail. 2. Support the right end of the rear overhead A/C unit while installing the two screws that secure the mounting bracket on the right end of the unit to the right roof rail. Tighten all of the mounting screws to 11.9 Nm (105 in. lbs.). 3. Plug in the rear overhead A/C unit wire harness connector located at the left side of the unit. 4. Connect the B-pillar drain hoses to the way fittings on each side of the rear overhead A/C unit. 5. Remove the tape or plugs from block fittings at the top of the B-pillar refrigerant line unit, and from the fittings on the rear overhead A/C unit. Install the B-pillar refrigerant line block fittings over the one stud on the rear overhead A/C unit. Install the bolt holding the suction line, and secure the connections with the mounting nuts. Tighten the mounting nuts to 11.3 Nm (100 in. lbs.). 6. Reinstall the headliner in the passenger compartment of the vehicle. 7. Connect the battery negative cable. 8. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, Evacuating the A/C System, See: Service and Repair/Refrigerant System Evacuate 9. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, A/C System Charge, See: Service and Repair/Refrigerant System Charge NOTE: If the rear overhead A/C unit 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications Receiver Dryer: Specifications Front Liquid Line Block Mounting Screws 120 in.lb Filter-Drier Bracket Mounting Screw 60 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications > Page 5298 Receiver Dryer: Locations Filter-Drier Remove/Install 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications > Page 5299 Receiver Dryer: Description and Operation SYSTEM DESCRIPTION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications > Page 5300 Receiver Dryer: Service and Repair WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Filter-Drier Remove/Install 3. Remove the screws that secure the front and rear liquid line block fittings to the filter-drier inlet and outlet. Disengage the block fittings from the filter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Remove the screw that secures the filter-drier mounting bracket to the front fender wheelhouse front extension. 5. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R134a Single Capacity ........................................................................................................................ ........................................ 0.79 kg (28 oz. or 1.75 lbs) R134a Dual Capacity ........................................................................................................................... ....................................... 0.85 kg (30 oz. or 1.87 lbs) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 5305 Refrigerant: Fluid Type Specifications Hydrofluorocarbon (HFC), ................................................................................................................... ............................................... R-134a liquefied gas Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Specifications Refrigerant Filter: Specifications Tighten the front liquid line block mounting screw to 13.5 Nm (120 in. lbs.). Tighten the filter drier bracket mounting screw to 6.8 Nm (60 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Specifications > Page 5309 Refrigerant Filter: Locations Filter-Drier Remove/Install 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Specifications > Page 5310 Refrigerant Filter: Description and Operation SYSTEM DESCRIPTION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Specifications > Page 5311 Refrigerant Filter: Service and Repair WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Filter-Drier Remove/Install 3. Remove the screws that secure the front and rear liquid line block fittings to the filter-drier inlet and outlet. Disengage the block fittings from the filter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Remove the screw that secures the filter-drier mounting bracket to the front fender wheelhouse front extension. 5. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil Capacities Chart Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 5316 Refrigerant Oil: Fluid Type Specifications Synthetic-based, Polyalkylene Glycol .................................................................................................. ......................................................................... SP-20 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 5317 Refrigerant Oil: Service and Repair 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations High Pressure Cut-Off Switch Remove/Install The high pressure cut-off switch is located on the discharge line near the compressor. Low Pressure Cut-Off Switch Remove/Install The low pressure cycling clutch switch is located on the side near the top of the accumulator. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5322 High Pressure Sensor / Switch: Description and Operation SYSTEM OPERATION High Pressure Cut-off Switch The high pressure cut-off switch is located on the discharge line near the compressor. The switch is screwed onto a fitting that contains a Schrader-type valve, which allows the switch to be serviced without discharging the refrigerant system. The discharge line fitting is equipped with an O-ring to seal the switch connection. The high pressure cut-off switch is connected in series electrically with the electronic cycling clutch switch and the low pressure cut-off switch 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 discharge line pressure approaches high levels. The high pressure cut-off switch contacts will open when the discharge line pressure rises above about 3100 to 3375 kPa (450 to 490 psi). The switch contacts will close when the discharge line pressure drops to about 1860 to 2275 kPa (270 to 330 psi). The high pressure cut-off switch is a factory-calibrated unit. The switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5323 High Pressure Sensor / Switch: Testing and Inspection Before performing diagnosis of the high pressure cut-off switch, verify that the refrigerant system has the correct refrigerant charge. 1. Disconnect and isolate the battery negative cable. 2. Unplug the high pressure cut-off switch wire harness connector from the switch on the refrigerant system fitting. 3. Check for continuity between the two terminals of the high pressure cut-off switch. There should be continuity. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5324 High Pressure Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. High Pressure Cut-Off Switch Remove/Install 2. Unplug the wire harness connector from the high pressure cut-off switch, which is mounted to a fitting on the discharge line between the compressor and the condenser inlet. 3. Unscrew the high pressure cut-off switch from the discharge line fitting. 4. Remove the high pressure cut-off 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 discharge 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 high pressure cut-off switch on the discharge line fitting. 3. Plug the wire harness connector into the high pressure cut-off switch. 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Electronic Cycling Clutch Switch Low Pressure Sensor / Switch: Locations Electronic Cycling Clutch Switch Low Pressure Cut-Off Switch Remove/Install The Electronic Cycling Clutch Switch (ECCS) is mounted to the outboard side of the thermal expansion valve in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Electronic Cycling Clutch Switch > Page 5329 Low Pressure Sensor / Switch: Locations Low Pressure Cycling Clutch Switch High Pressure Cut-Off Switch Remove/Install The high pressure cut-off switch is located on the discharge line near the compressor. Low Pressure Cut-Off Switch Remove/Install The low pressure cycling clutch switch is located on the side near the top of the accumulator. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Electronic Cycling Clutch Switch Low Pressure Sensor / Switch: Description and Operation Electronic Cycling Clutch Switch Freeze-Up Control = Electronic Clutch Cycling Switch (ECCS) mounted on expansion valve SYSTEM DESCRIPTION Electronic Cycling Clutch Switch The Electronic Cycling Clutch Switch (ECCS) is mounted to the outboard side of the thermal expansion valve in the engine compartment. A thermistor probe within a capillary tube on the switch is inserted into a well on the side of the expansion valve filled with a thermally-conductive grease. This arrangement allows the ECCS to monitor the temperature of the expanded refrigerant entering the evaporator. The function of the ECCS is to prevent refrigerant temperatures from becoming so low that condensation freezes on the evaporator fins. This condition is referred to as evaporator icing. Evaporator icing reduces air conditioning system air flow and cooling performance. The ECCS is connected in series electrically with the heater-A/C mode control switch, the low pressure cut-off switch and the high pressure cut-off switch between ground and the Powertrain Control Module (PCM). The ECCS will open when it monitors a refrigerant temperature below about 2.9° C (37.2° F), and will close again when the refrigerant temperature reaches about 4.3° C (39.7° F). The opening and closing of the ECCS signals the PCM to cycle the compressor clutch on and off through the compressor clutch relay. The ECCS is a factory sealed and calibrated unit and cannot be adjusted or repaired. If faulty or damaged, the ECCS must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Electronic Cycling Clutch Switch > Page 5332 Low Pressure Sensor / Switch: Description and Operation Low Pressure Cut-Off Switch SYSTEM OPERATION Low Pressure Cycling Clutch Switch The low pressure cycling clutch switch is located on the side near the top of the accumulator. The switch is screwed onto an accumulator fitting that contains a Schrader-type valve, which allows the switch to be serviced without discharging the refrigerant system. The accumulator fitting is equipped with an O-ring to seal the switch connection. The low pressure cycling clutch switch is connected in series electrically with the high pressure cut-off switch and 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 regulates the refrigerant system pressure and controls evaporator temperature. Controlling evaporator temperature prevents condensate water on the evaporator fins from freezing and obstructing air conditioning system air flow. The low pressure cycling clutch switch contacts will open when the suction pressure is about 141 kPa (20.5 psi) or lower. The switch contacts will close when the suction pressure rises to about 234 to 262 kPa (34 to 38 psi) or above. Lower ambient temperatures, below about -1° C (30° F), will also cause the switch contacts to open. This is due to the pressure/temperature relationship of the refrigerant in the system. The low pressure cycling clutch switch is a factory-calibrated unit. It cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Testing and Inspection > Low Pressure Cut-Off Switch Low Pressure Sensor / Switch: Testing and Inspection Low Pressure Cut-Off Switch Before performing diagnosis of the low pressure cut-off switch, remember that lower ambient temperatures, below about -1° C (30° F), 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 low pressure cut-off switch wire harness connector from the switch on the suction line jumper fitting. 3. Install a jumper wire between the two cavities of the low pressure cut-off switch wire 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 low pressure cut-off switch. There should be continuity with a suction pressure (low side) reading of 89.6 to 186.1 kPa (13 to 27 psi) or above, and no continuity with a suction pressure reading of 68.9 kPa (10 psi) or below. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Testing and Inspection > Low Pressure Cut-Off Switch > Page 5335 Low Pressure Sensor / Switch: Testing and Inspection Electronic Cycling Clutch Switch (Front Unit Only) Use a volt/ohmmeter to test the electronic cycling clutch switch. Verify that the refrigerant system has the correct refrigerant charge. Check that both the low and high pressure cut-off switches are functional as described in the Diagnosis and Testing before testing the electronic cycling clutch switch. 1. Disconnect and isolate the battery negative cable. Unplug the wire harness connectors at the electronic cycling clutch switch and the high pressure cut-off switch. Check for continuity between the C90A circuit cavities in the body half of the electronic cycling clutch switch wire harness connector and the high pressure cut-off switch wire harness connector. There should be continuity If OK, go to Step 2. If not OK, repair the open circuit as required. 2. Unplug the wire harness connector at the low pressure cut-off switch. Check for continuity between the C2 circuit cavities in the body half of the electronic cycling clutch switch wire harness connector and the low pressure cut-off switch wire harness connector. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit as required. 3. Plug in the wire harness connectors at the low pressure cut-off and high pressure cut-off switches. Connect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (RUN) circuit cavity in the body half of the electronic cycling clutch switch wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit to the junction block as required. 4. Plug in the wire harness connector at the electronic cycling clutch switch. With the ambient temperature from 20 - 30 °C (68 - 90 °F), start the engine and set the heater-A/C mode control switch in any A/C position. If the compressor clutch fails to engage, use a DRB III scan tool and the proper Diagnostic Procedures to check the Powertrain Control Module (PCM) and its inputs and outputs. If the compressor clutch engages, the clutch should cycle on and off two to three times per minute. If the clutch fails to cycle at this rate in these ambient temperatures, replace the faulty electronic cycling clutch switch. NOTE: It the ambient temperature is above 32 °C (90 °F) the compressor clutch may stay engaged and not cycle due to the high heat load. This condition is normal. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Electronic Cycling Clutch Switch Replacement Low Pressure Sensor / Switch: Service and Repair Electronic Cycling Clutch Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Electronic Cycling Clutch Switch Remove/Install 2. Unplug the wire harness connector from the electronic cycling clutch switch near the expansion valve. 3. Remove and discard the fastener that secures the electronic cycling clutch switch to the outboard side of the expansion valve. 4. Pull the electronic cycling clutch switch away from the side of the expansion valve far enough for the thermistor probe capillary tube to clear the well in the expansion valve. The washer bottle may have to be removed. NOTE: The capillary tube well in the expansion valve is tilled with a special thermally-conductive grease. This grease should be removed from the old parts and reused on the new parts whenever the electronic cycling clutch switch or the expansion valve are replaced. INSTALLATION 1. Insert the thermistor probe capillary tube of the electronic cycling clutch switch into the well on the outboard side of the expansion valve. 2. Install the electronic cycling clutch switch to the expansion valve and secure it with a new fastener. 3. Plug the wire harness connector into the electronic cycling clutch switch. 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Electronic Cycling Clutch Switch Replacement > Page 5338 Low Pressure Sensor / Switch: Service and Repair Low Pressure Cut-Out Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Low Pressure Cut-Off Switch Remove/Install 2. Unplug the wire harness connector from the low pressure cut-off switch on the suction line jumper near the expansion valve. 3. Unscrew the low pressure cut-off switch from the fitting on the suction line jumper. 4. Remove the O-ring seal from the suction line jumper fitting and discard. INSTALLATION 1. Lubricate a new O-ring seal with clean refrigerant oil and install it on the suction line jumper 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 low pressure cut-off switch on the suction line jumper fitting. The switch should be hand-tightened onto the fitting. 3. Plug the wire harness connector into the low pressure cut-off switch. 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Component Locations Blower Motor Relay: Component Locations Power Distribution Center The blower motor relay is located in the PDC in the engine compartment. The high speed blower motor relay is located in the relay and fuse block, which is attached to the back of the junction block, under the left side of the instrument panel in the passenger compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Component Locations > Page 5344 Blower Motor Relay: Connector Locations Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Component Locations > Page 5345 Blower Motor Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 5346 Blower Motor Relay: Description and Operation SYSTEM DESCRIPTION The blower motor relay is an International Standards Organization (ISO)-type relay. The relay is an electromechanical device that switches battery current from a fuse in the Power Distribution Center (PDC) directly to the blower motor. The relay is energized when the relay coil is provided a voltage signal by the ignition switch. This arrangement reduces the amount of battery current that must flow through the ignition switch. The blower motor relay control circuit is protected by a fuse located in the junction block. When the relay is de-energized, the blower motor receives no battery current. The blower motor relay is located in the PDC in the engine compartment. Refer to the PDC label for blower motor relay identification and location. The blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. High Speed Blower Motor Relay The front blower motor electrical circuit uses a high speed blower motor relay. The high speed blower motor relay is an International Standards Organization (ISO)-type relay. The relay is an electromechanical device that switches the blower motor to ground, bypassing the remainder of the blower motor feed circuit. The high speed blower motor relay is energized when the relay coil is provided a ground signal by the blower motor switch, and a battery feed from the ignition switch. When the relay is de-energized, the front blower motor ground feed is routed through the front blower motor switch and the blower motor resistor. The high speed blower motor relay is located in the relay and fuse block, which is attached to the back of the junction block, under the left side of the instrument panel in the passenger compartment. The high speed blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 5347 Blower Motor Relay: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Relay Test Blower Motor Relay The high speed blower motor relay is located in the relay and fuse block, which is attached to the back of the junction block, under the left side of the instrument panel in the passenger compartment. Remove the high speed blower motor relay from the relay and fuse block as described 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 Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the ground side of the blower motor. There should be continuity between the ground circuit cavity of the blower motor wire harness connector and the relay and fuse block cavity for relay terminal 30 at all times. If OK, go to Step 2. If not OK, repair the open circuit to the blower motor as required. 2. The relay normally closed terminal cavity (87A) is not used for this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to ground. When the relay is energized, terminal 87 is connected to terminal 30 and provides a direct path to ground for the blower motor. There should be continuity between the relay and fuse block cavity for terminal 87 and ground at all times. If OK, go to Step 4. If not OK, repair the open circuit to ground as required. 4. The coil battery terminal cavity (86) is connected to the ignition switch. When the ignition switch is placed in the On position, fused ignition switch output is directed from a fuse in the junction block to the relay electromagnetic coil to energize the relay There should be battery voltage at the relay and fuse block 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 junction block fuse as required. 5. The coil ground terminal cavity (85) is connected to the high speed output circuit terminal of the blower motor switch. This terminal supplies the ground for the relay electromagnetic coil. There should be continuity between the relay and fuse block cavity for relay terminal 85 and the high speed output circuit terminal of the blower motor switch at all times. If not OK, repair the open circuit to the blower motor switch as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 5348 Blower Motor Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for blower motor relay identification and location. 4. Unplug the blower motor relay from the PDC. 5. Install the blower motor relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations Compressor Clutch Relay: Component Locations Power Distribution Center The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 5353 Compressor Clutch Relay: Connector Locations Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 5354 A/C Compressor Clutch Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation > A/C Compressor Clutch Relay Description Compressor Clutch Relay: Description and Operation A/C Compressor Clutch Relay Description SYSTEM DESCRIPTION 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 electronic cycling clutch switch, the low pressure cut-off switch, and the high pressure cut-off switch. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation > A/C Compressor Clutch Relay Description > Page 5357 Compressor Clutch Relay: Description and Operation A/C Compressor Clutch Relay-PCM Output Power Distribution Center (PDC) AIR CONDITIONING (A/C) CLUTCH RELAY-PCM OUTPUT The A/C relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. The Powertrain Control Module (PCM) activates the A/C compressor through the A/C clutch relay. The PCM regulates A/C compressor operation by switching the ground circuit for the A/C clutch relay on and off. When the PCM receives a request for A/C from A/C evaporator switch, it will adjust idle air control (IAC) motor position. This is done to increase idle speed. The PCM will then activate the A/C clutch through the A/C clutch relay. The PCM adjusts idle air control (IAC) stepper motor position to compensate for increased engine load from the A/C compressor. By switching the ground path for the relay on and off, the PCM is able to cycle the A/C compressor clutch. This is based on changes in engine operating conditions. If; during A/C operation, the PCM senses low idle speeds or a wide open throttle condition, it will de-energize the relay. This prevents A/C clutch engagement. The relay will remain de-energized until the idle speed increases or the wide open throttle condition exceeds 15 seconds or no longer exists. The PCM will also de-energize the relay if coolant temperature exceeds 125°C (257°F). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation > Page 5358 Compressor Clutch Relay: Testing and Inspection Relay Test Compressor Clutch Relay 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 Relay Circuit Test in the Diagnosis and Testing. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation > Page 5359 Compressor Clutch Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 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. 5. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service Precautions Control Module HVAC: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Ambient Temperature Sensor / Switch HVAC: Specifications Ambient Temperature Sensor Bracket to Radiator Yoke Screw 50 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 5367 Ambient Temperature Sensor / Switch HVAC: Locations Ambient Temperature Sensor Remove/Install The ambient temperature sensor is mounted on the right side of the radiator yoke behind the grille. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 5368 Ambient Air Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 5369 Ambient Temperature Sensor / Switch HVAC: Description and Operation DESCRIPTION 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. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. OPERATION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 5370 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 (231° 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. 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 kilohms. At 55° C (131° F), the sensor resistance is 2.488 kilohms. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 5371 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations Blower Motor Switch: Locations Rear Blower Motor Switch Remove/Install The blower motor switch is mounted in the heater-A/C control panel Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 5375 Blower Motor Switch: Description and Operation SYSTEM DESCRIPTION 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. Rear The optional rear overhead A/C unit blower motor is controlled by a four position rotary-type blower motor switch, mounted by a snap fit in a hole in the headliner over the right front seat back. The switch allows the selection of one of three blower motor speeds and an Off position. The blower motor switch directs the blower motor ground path through the blower motor resistor. The blower motor switch cannot be repaired and, if faulty or damaged, the entire switch unit must be replaced. The blower motor switch has a replaceable incandescent-type illumination lamp bulb. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 5376 Blower Motor Switch: Testing and Inspection Front WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check for battery voltage at the 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. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the heater-A/C control from the instrument panel. Check for continuity between the ground circuit cavity of the heater-A/C control wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 3. With the heater-A/C control wire harness connector unplugged, place the heater-A/C mode control switch knob to any position except the Off position. Check for continuity between the ground circuit terminal and each of the blower motor driver circuit terminals of the heater-A/C control as you move the blower motor switch knob to each of the four speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the blower driver circuits between the heater-A/C control connector and the blower motor resistor as required. If not OK, replace the faulty heater-A/C control unit. Rear 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the rear blower motor switch from the headliner. Check for continuity between the ground circuit cavity of the rear blower motor switch wire harness connector and a good ground. There should be continuity If OK, go to Step 2. If not OK, repair the open circuit to ground as required. 2. With the rear blower motor switch wire harness connector unplugged, place the rear blower motor switch knob to any position except the Off position. Check for continuity between the ground circuit terminal and each of the blower motor driver circuit terminals of the rear blower motor switch as you move the blower motor switch knob to each of the three speed positions. There should be continuity at each driver circuit terminal in only one blowermotor switch speed position. If OK, test and repair the rear blower driver circuits between the rear blower motor switch wire harness connector and the blower motor resistor as required. If not OK, replace the faulty rear blower motor switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 5377 Blower Motor Switch: Service and Repair The rear blower motor switch is used only on models with the optional rear overhead air conditioning unit. REMOVAL 1. Disconnect and isolate the battery negative cable. Rear Blower Motor Switch Remove/Install 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 blower motor switch 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 1. Plug the wire harness connector into the back of the rear blower motor switch. 2. Check 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations High Pressure Cut-Off Switch Remove/Install The high pressure cut-off switch is located on the discharge line near the compressor. Low Pressure Cut-Off Switch Remove/Install The low pressure cycling clutch switch is located on the side near the top of the accumulator. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5382 High Pressure Sensor / Switch: Description and Operation SYSTEM OPERATION High Pressure Cut-off Switch The high pressure cut-off switch is located on the discharge line near the compressor. The switch is screwed onto a fitting that contains a Schrader-type valve, which allows the switch to be serviced without discharging the refrigerant system. The discharge line fitting is equipped with an O-ring to seal the switch connection. The high pressure cut-off switch is connected in series electrically with the electronic cycling clutch switch and the low pressure cut-off switch 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 discharge line pressure approaches high levels. The high pressure cut-off switch contacts will open when the discharge line pressure rises above about 3100 to 3375 kPa (450 to 490 psi). The switch contacts will close when the discharge line pressure drops to about 1860 to 2275 kPa (270 to 330 psi). The high pressure cut-off switch is a factory-calibrated unit. The switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5383 High Pressure Sensor / Switch: Testing and Inspection Before performing diagnosis of the high pressure cut-off switch, verify that the refrigerant system has the correct refrigerant charge. 1. Disconnect and isolate the battery negative cable. 2. Unplug the high pressure cut-off switch wire harness connector from the switch on the refrigerant system fitting. 3. Check for continuity between the two terminals of the high pressure cut-off switch. There should be continuity. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5384 High Pressure Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. High Pressure Cut-Off Switch Remove/Install 2. Unplug the wire harness connector from the high pressure cut-off switch, which is mounted to a fitting on the discharge line between the compressor and the condenser inlet. 3. Unscrew the high pressure cut-off switch from the discharge line fitting. 4. Remove the high pressure cut-off 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 discharge 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 high pressure cut-off switch on the discharge line fitting. 3. Plug the wire harness connector into the high pressure cut-off switch. 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Electronic Cycling Clutch Switch Low Pressure Sensor / Switch: Locations Electronic Cycling Clutch Switch Low Pressure Cut-Off Switch Remove/Install The Electronic Cycling Clutch Switch (ECCS) is mounted to the outboard side of the thermal expansion valve in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Electronic Cycling Clutch Switch > Page 5389 Low Pressure Sensor / Switch: Locations Low Pressure Cycling Clutch Switch High Pressure Cut-Off Switch Remove/Install The high pressure cut-off switch is located on the discharge line near the compressor. Low Pressure Cut-Off Switch Remove/Install The low pressure cycling clutch switch is located on the side near the top of the accumulator. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Electronic Cycling Clutch Switch Low Pressure Sensor / Switch: Description and Operation Electronic Cycling Clutch Switch Freeze-Up Control = Electronic Clutch Cycling Switch (ECCS) mounted on expansion valve SYSTEM DESCRIPTION Electronic Cycling Clutch Switch The Electronic Cycling Clutch Switch (ECCS) is mounted to the outboard side of the thermal expansion valve in the engine compartment. A thermistor probe within a capillary tube on the switch is inserted into a well on the side of the expansion valve filled with a thermally-conductive grease. This arrangement allows the ECCS to monitor the temperature of the expanded refrigerant entering the evaporator. The function of the ECCS is to prevent refrigerant temperatures from becoming so low that condensation freezes on the evaporator fins. This condition is referred to as evaporator icing. Evaporator icing reduces air conditioning system air flow and cooling performance. The ECCS is connected in series electrically with the heater-A/C mode control switch, the low pressure cut-off switch and the high pressure cut-off switch between ground and the Powertrain Control Module (PCM). The ECCS will open when it monitors a refrigerant temperature below about 2.9° C (37.2° F), and will close again when the refrigerant temperature reaches about 4.3° C (39.7° F). The opening and closing of the ECCS signals the PCM to cycle the compressor clutch on and off through the compressor clutch relay. The ECCS is a factory sealed and calibrated unit and cannot be adjusted or repaired. If faulty or damaged, the ECCS must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Electronic Cycling Clutch Switch > Page 5392 Low Pressure Sensor / Switch: Description and Operation Low Pressure Cut-Off Switch SYSTEM OPERATION Low Pressure Cycling Clutch Switch The low pressure cycling clutch switch is located on the side near the top of the accumulator. The switch is screwed onto an accumulator fitting that contains a Schrader-type valve, which allows the switch to be serviced without discharging the refrigerant system. The accumulator fitting is equipped with an O-ring to seal the switch connection. The low pressure cycling clutch switch is connected in series electrically with the high pressure cut-off switch and 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 regulates the refrigerant system pressure and controls evaporator temperature. Controlling evaporator temperature prevents condensate water on the evaporator fins from freezing and obstructing air conditioning system air flow. The low pressure cycling clutch switch contacts will open when the suction pressure is about 141 kPa (20.5 psi) or lower. The switch contacts will close when the suction pressure rises to about 234 to 262 kPa (34 to 38 psi) or above. Lower ambient temperatures, below about -1° C (30° F), will also cause the switch contacts to open. This is due to the pressure/temperature relationship of the refrigerant in the system. The low pressure cycling clutch switch is a factory-calibrated unit. It cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Testing and Inspection > Low Pressure Cut-Off Switch Low Pressure Sensor / Switch: Testing and Inspection Low Pressure Cut-Off Switch Before performing diagnosis of the low pressure cut-off switch, remember that lower ambient temperatures, below about -1° C (30° F), 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 low pressure cut-off switch wire harness connector from the switch on the suction line jumper fitting. 3. Install a jumper wire between the two cavities of the low pressure cut-off switch wire 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 low pressure cut-off switch. There should be continuity with a suction pressure (low side) reading of 89.6 to 186.1 kPa (13 to 27 psi) or above, and no continuity with a suction pressure reading of 68.9 kPa (10 psi) or below. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Testing and Inspection > Low Pressure Cut-Off Switch > Page 5395 Low Pressure Sensor / Switch: Testing and Inspection Electronic Cycling Clutch Switch (Front Unit Only) Use a volt/ohmmeter to test the electronic cycling clutch switch. Verify that the refrigerant system has the correct refrigerant charge. Check that both the low and high pressure cut-off switches are functional as described in the Diagnosis and Testing before testing the electronic cycling clutch switch. 1. Disconnect and isolate the battery negative cable. Unplug the wire harness connectors at the electronic cycling clutch switch and the high pressure cut-off switch. Check for continuity between the C90A circuit cavities in the body half of the electronic cycling clutch switch wire harness connector and the high pressure cut-off switch wire harness connector. There should be continuity If OK, go to Step 2. If not OK, repair the open circuit as required. 2. Unplug the wire harness connector at the low pressure cut-off switch. Check for continuity between the C2 circuit cavities in the body half of the electronic cycling clutch switch wire harness connector and the low pressure cut-off switch wire harness connector. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit as required. 3. Plug in the wire harness connectors at the low pressure cut-off and high pressure cut-off switches. Connect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (RUN) circuit cavity in the body half of the electronic cycling clutch switch wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit to the junction block as required. 4. Plug in the wire harness connector at the electronic cycling clutch switch. With the ambient temperature from 20 - 30 °C (68 - 90 °F), start the engine and set the heater-A/C mode control switch in any A/C position. If the compressor clutch fails to engage, use a DRB III scan tool and the proper Diagnostic Procedures to check the Powertrain Control Module (PCM) and its inputs and outputs. If the compressor clutch engages, the clutch should cycle on and off two to three times per minute. If the clutch fails to cycle at this rate in these ambient temperatures, replace the faulty electronic cycling clutch switch. NOTE: It the ambient temperature is above 32 °C (90 °F) the compressor clutch may stay engaged and not cycle due to the high heat load. This condition is normal. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Electronic Cycling Clutch Switch Replacement Low Pressure Sensor / Switch: Service and Repair Electronic Cycling Clutch Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Electronic Cycling Clutch Switch Remove/Install 2. Unplug the wire harness connector from the electronic cycling clutch switch near the expansion valve. 3. Remove and discard the fastener that secures the electronic cycling clutch switch to the outboard side of the expansion valve. 4. Pull the electronic cycling clutch switch away from the side of the expansion valve far enough for the thermistor probe capillary tube to clear the well in the expansion valve. The washer bottle may have to be removed. NOTE: The capillary tube well in the expansion valve is tilled with a special thermally-conductive grease. This grease should be removed from the old parts and reused on the new parts whenever the electronic cycling clutch switch or the expansion valve are replaced. INSTALLATION 1. Insert the thermistor probe capillary tube of the electronic cycling clutch switch into the well on the outboard side of the expansion valve. 2. Install the electronic cycling clutch switch to the expansion valve and secure it with a new fastener. 3. Plug the wire harness connector into the electronic cycling clutch switch. 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Electronic Cycling Clutch Switch Replacement > Page 5398 Low Pressure Sensor / Switch: Service and Repair Low Pressure Cut-Out Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Low Pressure Cut-Off Switch Remove/Install 2. Unplug the wire harness connector from the low pressure cut-off switch on the suction line jumper near the expansion valve. 3. Unscrew the low pressure cut-off switch from the fitting on the suction line jumper. 4. Remove the O-ring seal from the suction line jumper fitting and discard. INSTALLATION 1. Lubricate a new O-ring seal with clean refrigerant oil and install it on the suction line jumper 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 low pressure cut-off switch on the suction line jumper fitting. The switch should be hand-tightened onto the fitting. 3. Plug the wire harness connector into the low pressure cut-off switch. 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Service Port HVAC: Locations Liquid Line Remove/Install The high pressure service port is located on the liquid line between the condenser and the evaporator, near the front of the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 5402 Service Port HVAC: Description and Operation SYSTEM DESCRIPTION Refrigerant System Service Port 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 located on the compressor manifold, directly over the suction port of the compressor. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Locations Vacuum Check Valve HVAC: Locations Vacuum Supply One check valve is located near the vacuum fitting on the power brake booster. The second check valve is located at the heater and air conditioner take-out of the accessory vacuum supply line Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Locations > Page 5406 Vacuum Check Valve HVAC: Description and Operation SYSTEM DESCRIPTION Two vacuum check valves are installed in the accessory vacuum supply line in the engine compartment. One check valve is located near the vacuum fitting on the power brake booster. The second check valve is located at the heater and air conditioner take-out of the accessory vacuum supply line. The vacuum check valves are designed to allow vacuum to flow in only one direction through the accessory vacuum supply circuits. The use of the vacuum check valves help to maintain the system vacuum needed to retain the selected heater-A/C mode settings. The check valves will prevent the engine from bleeding down system vacuum through the intake manifold during extended heavy engine load (low engine vacuum) operation. The vacuum check valves cannot be repaired and, if faulty or damaged, they must be individually replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Locations > Page 5407 Vacuum Check Valve HVAC: Testing and Inspection 1. Remove the vacuum check valve that is to be tested. The valves are located in flue vacuum supply tube (black) at the power brake booster on the left side of the engine compartment, and in the heater and air conditioner vacuum take-out of the vacuum supply tube in the engine compartment. The vacuum check valve must be removed in order to perform the following tests. 2. Connect the test set vacuum supply hose to the heater-A/C control side of the valve. When connected to this side of the check valve no vacuum should pass and the test set gauge should return to the 27 kPa (8 in. Hg.) setting. If OK, go to step Step 3. If not OK, replace the faulty valve. 3. Connect the test set vacuum supply hose to the engine vacuum side of the valve. When connected to this side of the check valve, vacuum should flow through the valve without restriction. If not OK, replace the faulty valve. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Locations > Page 5408 Vacuum Check Valve HVAC: Service and Repair REMOVAL Vacuum Supply 1. Unplug the vacuum supply line connector at the vacuum check valve. 2. Note the orientation of the check valve in the vacuum supply line for correct reinstallation. 3. Unplug the vacuum check valve from the vacuum supply line fittings. 4. Reverse the removal procedures to install. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Specifications Vacuum Reservoir HVAC: Specifications Vacuum Reservoir Mounting Screws 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Specifications > Page 5412 Vacuum Reservoir HVAC: Locations The vacuum reservoir is mounted to the underside of the cowl plenum cover/grille panel in the right cowl plenum area. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Specifications > Page 5413 Vacuum Reservoir HVAC: Description and Operation SYSTEM DESCRIPTION The vacuum reservoir is mounted to the underside of the cowl plenum cover/grille panel in the right cowl plenum area. The cowl plenum cover/grille panel must be removed from the vehicle to access the vacuum reservoir for service. Engine vacuum is stored in the vacuum reservoir. The stored vacuum is used to operate the vacuum controlled vehicle accessories during periods of low engine vacuum such as when the vehicle is climbing a steep grade, or under other high engine load operating conditions. The vacuum reservoir cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Specifications > Page 5414 Vacuum Reservoir HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the wiper arms from the wiper pivots. Refer to Wiper Arm/Service and Repair of Wiper and Washer Systems for the procedures. Cowl Plenum Cover/Grille Panel Weatherstrip 3. Remove the weatherstrip along the front edge of the cowl plenum cover/grille panel and the cowl plenum panel. Cowl Plenum Cover/Grille Panel Remove/Install 4. Remove the four plastic nuts that secure the cowl plenum cover/grille panel to the studs on the cowl top panel near the base of the windshield. 5. Remove the one plastic rivet that secures the front corner on each side of the cowl plenum cover/grille panel to the cowl plenum panel. 6. Remove the one plastic push-in retainer that secures the rear corner on each side of the cowl plenum cover/grille panel to the windshield reveal molding. 7. Unsnap the slotted center hole on each side of the cowl plenum cover/grille panel from the adhesive- backed snap fastener. (If equipped: This feature may not be on all models). 8. Lift the cowl plenum cover/grille panel from the cowl top far enough to access the windshield washer nozzle and vacuum plumbing near the right end of the cowl plenum. 9. Disconnect the windshield washer supply hose at the in-line connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Specifications > Page 5415 Vacuum Reservoir 10. Disconnect the vacuum supply hose from the vacuum reservoir, which is secured to the underside of the right end of the cowl plenum cover/grille panel. 11. Remove the cowl plenum cover/grille panel from the vehicle. 12. Remove the three screws that secure the vacuum reservoir to the underside of the cowl plenum cover/grille panel. 13. Remove the vacuum reservoir from the cowl plenum cover/grille panel. 14. Reverse the removal procedures to install. Tighten the vacuum reservoir mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming Disconnect and isolate the battery negative cable. If the airbag module has not been deployed, wait two minutes for the system capacitor to discharge before further service. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 5422 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming 16-Way Data Link Connector - Typical 1. Make sure no one is in the vehicle. 2. Connect the negative battery terminal. 3. Connect the DRB scan tool to the 16-way data link wire harness connector. The connector is located on the driver side lower edge of the instrument panel, outboard of the steering column. 4. Turn the ignition switch to the ON position. Exit the vehicle with the DRB. Use the latest version of the proper DRB cartridge. 5. Erase the stored DTC data. If any problems remain, the stored DTC data will not erase. 6. With the ignition switch still in the ON position, make sure nobody is in the vehicle. 7. From outside of the vehicle (away from the airbag modules in case of an accidental deployment) turn the ignition switch to the OFF position for about 10 seconds, and then back to the ON position. Observe the airbag indicator lamp in the instrument cluster. It should light for six to 8 seconds, and then go out. This indicates that the airbag system is functioning normally. NOTE: If the airbag indicator lamp fails to light, or lights and stays on, there is an airbag system malfunction. Refer to the proper Diagnostic Procedures to diagnose the problem. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Driver Airbag - Trim Cover Service > Page 5427 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Driver Airbag - Trim Cover Service > Page 5428 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Driver Airbag - Trim Cover Service > Page 5429 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 5430 Air Bag: Specifications Driver's Side Airbag Module Mounting Screws (2) 90 in.lb Airbag Housing Stud Nuts 90 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 5431 Air Bag: Diagrams Driver Airbag Squib Passenger Airbag Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 5432 Air Bag: Description and Operation DRIVER SIDE AIRBAG MODULE DESCRIPTION The driver side airbag module protective trim cover is the most visible part of the driver side airbag system. The driver side airbag module is mounted directly to the steering wheel. Located under the airbag module trim cover are the horn switch, the folded airbag cushion, and the airbag cushion supporting components. The resistive membrane-type horn switch is secured with heat stakes to the inside surface of the airbag module trim cover, between the trim cover and the folded airbag cushion. The driver side airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The driver side airbag module trim cover and the horn switch are available as a unit for service replacement. OPERATION The driver side airbag module includes a stamped metal housing to which the cushion and an inflator unit are attached and sealed. The conventional pyrotechnic-type inflator assembly is mounted to studs on the back of the airbag module housing. The inflator seals the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the proper electrical signal. Following an airbag deployment, the airbag cushion quickly deflates by venting this gas towards the instrument panel through the porous fabric material used on the steering wheel side of the airbag cushion. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. The inside of the trim cover has locking blocks molded into it that engage a lip on the airbag module metal housing.Two stamped metal retainers then fit over the inflator mounting studs on the back of the airbag module housing and are engaged in slots on the inside of the cover, securely locking the trim cover into place. The trim cover will split at predetermined breakout lines, then fold back out of the way along with the horn switch upon airbag deployment. PASSENGER SIDE AIRBAG MODULE DESCRIPTION The passenger side airbag door on the instrument panel above the glove box is the most visible part of the passenger side airbag system. Located under the airbag door are the passenger side airbag cushion and the airbag cushion supporting components. The passenger side airbag module includes an extruded aluminum housing within which the cushion and inflator are mounted and sealed. The airbag housing extrusion also includes two flanges. The flanges, one at the top and one at the bottom, serve as the mounting brackets for the module. Two stamped metal brackets, one on each end of the housing, enclose the cushion and inflator. The passenger side airbag module upper bracket is secured beneath the instrument panel top pad with rivets to a flange and bracket on the passenger side airbag door. The lower bracket is secured with screws to the instrument panel structural duct. Following a passenger side airbag deployment, the passenger side airbag module and the instrument panel assembly must be replaced. The passenger side airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. OPERATION The hybrid-type inflator assembly includes a small canister of highly compressed argon gas. The inflator seals the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the proper electrical signal. Following an airbag deployment, the airbag cushion quickly deflates by venting this gas through the porous fabric material used on each end panel of the airbag cushion. The molded plastic passenger side airbag door is secured to the instrument panel top cover with rivets. The airbag door has predetermined breakout lines concealed beneath its decorative cover. Upon airbag deployment, the airbag door will split at the breakout lines and the door will pivot out of the way The passenger side airbag door is serviced only as a unit with the instrument panel top cover. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Side Airbag Module Replacement Air Bag: Service and Repair Driver Side Airbag Module Replacement The following procedure is for replacement of a faulty or damaged driver side airbag module. If the driver side airbag has been deployed, the clockspring and the steering column assembly must also be replaced. Refer to Clockspring/Service and Repair for the additional service procedures for the clockspring. WARNING: - THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-BAG 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 AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - WHEN REMOVING A DEPLOYED AIRBAG MODULE, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG MODULE AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. REMOVAL 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. Driver Side Airbag Module Remove/Install 2. From the underside of the steering wheel, remove the two screws that secure the driver side airbag module to the steering wheel. 3. Pull the airbag module away from the steering wheel far enough to access the two wire harness connectors on the back of the airbag module. 4. Disconnect the clockspring horn switch wire harness connector from the horn switch feed wire connector, which is located on the back of the airbag module. 5. The clockspring airbag wire harness connector is a tight snap-fit into the airbag module connector receptacle, which is located on the airbag inflator on the back of the airbag module. Firmly grasp and pull or gently pry on the clockspring airbag wire harness connector to disconnect it from the airbag module. Do not pull on the clockspring wire harness to disengage the connector from the airbag module connector receptacle. 6. Remove the driver side airbag module from the steering wheel. 7. If the driver side airbag has been deployed, the clockspring and the steering column must be replaced. Refer to Clockspring/Service and Repair for the clockspring service procedures. INSTALLATION WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER SIDE AIRBAG MODULE, OR BECOMING ENTRAPPED BETWEEN THE AIRBAG CUSHION AND THE DRIVER SIDE AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - THE DRIVER SIDE AIRBAG MODULE 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 AIR BAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Side Airbag Module Replacement > Page 5435 OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. 1. When installing the driver side airbag module, reconnect the clockspring airbag wire harness connector to the airbag module 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. 2. Reconnect the clockspring horn switch wire harness connector to the horn switch feed wire connector, which is located on the back of the airbag module. 3. Carefully position the driver side airbag module in the steering wheel. Be certain that the clockspring wire harnesses in the steering wheel hub area are not pinched between the airbag module and the steering wheel. 4. From the underside of the steering wheel, install and tighten the two driver side airbag module mounting screws. Tighten the screws to 10.2 Nm (90 in. lbs.). 5. Do not reconnect the battery negative cable at this time. Refer to Airbag System in the Diagnosis and Testing for the proper procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Side Airbag Module Replacement > Page 5436 Air Bag: Service and Repair Driver Side Airbag Module Trim Cover Replacement The horn switch is integral to the driver side air-bag module trim cover. If either component is faulty or damaged, the entire driver side airbag module trim cover and horn switch unit must be replaced. WARNING: - THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-BAG 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 AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE HORN SWITCH IS INTEGRAL TO THE AIR-BAG MODULE TRIM COVER. SERVICE OF THIS COMPONENT SHOULD BE PERFORMED ONLY BY CHRYSLER-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. REMOVAL 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 side airbag module from the steering wheel. Refer to Driver Side Airbag Module Replacement for the procedures. Driver Side Airbag Trim Cover Retainer Nuts Remove/Install 3. Remove the four nuts that secure the upper and lower trim cover retainers to the studs on the back of the driver side airbag housing. Airbag Trim Cover Retainer Nuts Remove/Install 4. Remove the upper and lower trim cover retainers from the airbag housing studs. 5. Remove the horn switch ground wire eyelet from the upper airbag housing stud. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Side Airbag Module Replacement > Page 5437 Airbag Trim Cover Remove/Install 6. Disengage the six trim cover locking blocks from the lip around the outside edge of the driver side airbag housing and remove the housing from the cover. INSTALLATION WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER SIDE AIRBAG MODULE, OR BECOMING ENTRAPPED BETWEEN THE AIR BAG CUSHION AND THE DRIVER SIDE AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - THE DRIVER SIDE AIR BAG MODULE 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 AIR BAG DEPLOYMENT. 1. Carefully position the driver side airbag module in the trim cover. Be certain that the horn switch feed and ground wires are not pinched between the airbag housing and the trim cover locking blocks. Driver Side Airbag Trim Cover Locking Blocks Engaged Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Side Airbag Module Replacement > Page 5438 2. Engage the upper and lower trim cover locking blocks with the lip of the driver side airbag housing, then engage the locking blocks on each side of the trim cover with the lip of the housing. Be certain that each of the locking blocks is fully engaged on the lip of the airbag housing. 3. Install the horn switch ground wire eyelet over the upper airbag housing stud. 4. Install the upper and lower airbag trim cover retainers over the airbag housing studs. Be certain that the tabs on each retainer are engaged in the retainer slots of the upper and lower trim cover locking blocks. 5. Install and tighten the trim cover retainer mounting nuts on the airbag housing studs. Tighten the nuts to 10 Nm (90 in. lbs.). 6. Install the driver side airbag module onto the steering wheel. Refer to Driver Side Airbag Module Replacement for the procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Side Airbag Module Replacement > Page 5439 Air Bag: Service and Repair Passenger Side Airbag Module Replacement The following procedure is for replacement of a faulty or damaged passenger side airbag module. If the passenger side airbag module has been deployed, the instrument panel assembly must be replaced. The instrument panel assembly includes the passenger side airbag module and the passenger side airbag door. Refer to Instrument Panel Assembly Replacement of Instrument Panel Systems for the instrument panel assembly service procedures. WARNING: - THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTRO MECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-BAG 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 AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - WHEN REMOVING A DEPLOYED AIRBAG MODULE, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG MODULE AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. REMOVAL 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 instrument panel top cover and the passenger side airbag module from the instrument panel as a unit. Refer to Instrument Panel Top Cover Replacement of Instrument Panel Systems for the procedures. 3. Place the instrument panel top cover assembly on a suitable work surface. Be certain to take the proper precautions to protect the top cover from any possible cosmetic damage. Passenger Side Airbag Module Vents 4. Apply masking tape over the passenger side airbag module vents on each end of the module. The tape will help to prevent foreign material from entering the airbag module through the vents during removal and installation of the module from the upper airbag door flange and bracket. WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE PASSENGER SIDE AIRBAG MODULE, OR BECOMING ENTRAPPED BETWEEN THE INSTRUMENT PANEL TOP COVER AND THE PASSENGER SIDE AIRBAG MODULE. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Side Airbag Module Replacement > Page 5440 Passenger Side Airbag Module Rivets 5. Using a suitable center punch, carefully drive out the mandrels from the four rivets that secure the passenger side airbag module upper mounting bracket to the upper airbag door flange and bracket on the instrument panel top cover. 6. Use a suitable pair of rivet cutters or a large pair of side cutters to cut the rims or heads off of the four rivets that secure the passenger side airbag module upper mounting bracket to the upper airbag door flange and bracket on the underside of the instrument panel top cover. WARNING: DO NOT USE A DRILL TO REMOVE THE RIVETS. SPARKS CREATED WHEN DRILLING COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALSO, METAL SHAVINGS CREATED WHEN DRILLING COULD ENTER THE PASSENGER SIDE AIRBAG MODULE AND RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. Passenger Side Airbag Module Remove/Install 7. Remove the passenger side airbag module from the upper airbag door flange and bracket on the underside of the instrument panel top cover. INSTALLATION WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE PASSENGER SIDE AIRBAG MODULE, OR BECOMING ENTRAPPED BETWEEN THE AIRBAG CUSHION AND THE PASSENGER SIDE AIRBAG DOOR. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - THE PASSENGER SIDE AIRBAG DOOR MUST NEVER BE PAINTED. REPLACEMENT INSTRUMENT PANEL ASSEMBLIES AND TOP COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE PASSENGER SIDE 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 side airbag module upper mounting bracket to the upper airbag door flange and bracket on the underside of the instrument panel top cover. NOTE: Use only the correct rivets that are specified in the Chrysler Mopar Parts Catalog, or that are supplied in the service package with the new Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Side Airbag Module Replacement > Page 5441 airbag module and/or the new instrument panel top cover when installing the passenger side airbag module. 2. Secure the passenger side airbag module upper mounting bracket to the upper airbag door flange and bracket with four rivets. 3. Remove the masking tape applied to the passenger side airbag module vents during the removal procedures. 4. install the instrument panel top cover and the passenger side airbag module onto the instrument panel as a unit. Refer to Instrument Panel Top Cover Replacement of Instrument Panel Systems for the procedures. 5. Be certain that the passenger side airbag module wire harness connector is fully engaged with and latched to the instrument panel wire harness connector. 6. Do not reconnect the battery negative cable at this time. Refer to Airbag System in the Diagnosis and Testing for the proper procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications ACM to Transmission Tunnel Bracket Mounting Screws (3) 105 in.lb Instrument Panel Wiring Harness Ground Eyelet to Transmission Tunnel Bracket Screw 30 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 5445 Air Bag Control Module: Locations Airbag Control Module Remove/Install The Airbag Control Module (ACM) is secured with screws to a mount welded onto the floor panel transmission tunnel behind the instrument panel center support bracket in the passenger compartment of the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 5446 Airbag Control Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 5447 Air Bag Control Module: Description and Operation DESCRIPTION The Airbag Control Module (ACM) is secured with screws to a mount welded onto 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 cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. OPERATION The microprocessor in the ACM contains the airbag system logic. The airbag system logic includes On-Board Diagnostics (OBD), and the ability to communicate with the instrument cluster circuitry over the Chrysler Collision Detection (CCD) data bus to control the airbag indicator lamp. The microprocessor continuously monitors all of the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster over the CCD data bus to turn on the airbag indicator lamp. Refer to Instrument Cluster in the Instrument Panel Systems for more information on the airbag indicator lamp. One electronic impact sensor is used in this airbag system. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. 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. In addition to the electronic impact sensor, there is an electromechanical sensor within the ACM called a safing sensor. The safing sensor is a normally open series switch located in the airbag deployment circuit of the ACM. This sensor detects impact energy of a lesser magnitude than the electronic impact sensor, and must be closed in order for the airbags to deploy The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the airbags for up to one second following a battery disconnect or failure during an impact. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact, if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 5448 Air Bag Control Module: Service and Repair WARNING: - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIR BAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR BAG 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 AIR-BAG 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 AIR BAG 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. REMOVAL 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 center support bracket from the instrument panel. Refer to Instrument Panel Center Support Bracket Replacement of Instrument Panel Systems for the procedures. Airbag Control Module Remove/Install 3. Remove the screw that secures the instrument panel wire harness ground eyelet to the left side of the mount that is welded onto the floor panel transmission tunnel. 4. Disconnect the instrument panel wire harness connector from the Airbag Control Module (ACM). To disconnect the instrument panel wire harness connector from the ACM: a. Slide the red Connector Position Assurance (CPA) lock on the top of the connector toward the side of the vehicle. b. Depress the connector latch tab and pull the connector straight away from the ACM connector receptacle. 5. Remove the three screws that secure the ACM to the mount that is welded onto the floor panel transmission tunnel. 6. Remove the ACM from the mount on the floor panel transmission tunnel. INSTALLATION 1. Carefully position the ACM to the mount that is welded onto the floor panel transmission tunnel. When the ACM is correctly positioned the arrow on the ACM label will be pointed forward in the vehicle. 2. Install and tighten the three screws that secure the ACM to the mount that is welded onto the floor panel transmission tunnel. Tighten the screws to 11.8 Nm (105 in. lbs.). 3. Install and tighten the screw that secures the instrument panel wire harness ground eyelet to the left side of the mount that is welded onto the floor panel transmission tunnel. Tighten the screw to 3.4 Nm (30 in. lbs.). 4. Reconnect the instrument panel wire harness connector to the ACM connector receptacle. Be certain that the connector latch and the red CPA lock are fully engaged. 5. Do not reconnect the battery negative cable at this time. Refer to Airbag System in the Diagnosis and Testing for the proper procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5453 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5454 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5455 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5456 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5457 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5458 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5459 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5460 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5461 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5462 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5463 PARTS REQUIRED: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5464 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5465 POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Page 5466 Passenger Airbag On/Off Switch C1 (Switch Side) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 5471 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5472 Clockspring Assembly / Spiral Cable: Specifications Steering Wheel Mounting Nut 45 ft.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5473 Clockspring Assembly / Spiral Cable: Diagrams Clockspring No. 1-C1 Clockspring (Clockspring Side) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5474 Clockspring Assembly / Spiral Cable: Service Precautions WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-BAG 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 AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5475 Clockspring Assembly / Spiral Cable: Description and Operation DESCRIPTION The clockspring assembly is secured with two integral plastic latches onto the steering column lock housing near the top of the steering column behind the steering wheel. The clockspring is used to maintain a continuous electrical circuit between the fixed clockspring wire harness on the steering column and several electrical components that rotate with the steering wheel. The rotating components include the driver side airbag module, the horn switch and, if the vehicle is so equipped, the vehicle speed control switches and/or the remote radio switches. The clockspring cannot be repaired. If the clock- spring is faulty, damaged, or if the driver side airbag has been deployed, the clockspring must be replaced. OPERATION The clockspring assembly consists of a plastic case which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds like a clockspring with the steering wheel rotation. The electrically conductive tape consists of several fine gauge copper wire leads sandwiched between two narrow strips of plastic film. Like the clockspring in a timepiece, the clockspring tape has travel limits and can be damaged by being wound too tightly. 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 other steering components so that it can operate within its designed travel limits. However, if the clockspring is removed for service or if the steering column is disconnected from the steering gear allowing the clockspring tape to change position relative to the other steering components, it must be re-centered following completion of the service or it may be damaged. Refer to Clockspring Centering in the Adjustments for the proper centering procedures. Service replacement clocksprings are shipped precentered and with a piece of tape covering the depressed clockspring auto-locking tabs. This tape should not be removed until the clockspring has been installed on the steering column. If the tape is removed before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5476 Clockspring Assembly / Spiral Cable: Adjustments Clockspring Centering 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. 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 the service or the clockspring tape may be damaged. Service replacement clocksprings are shipped precentered and with a piece of tape covering the depressed auto-locking tabs. This tape should not be removed until the clockspring has been installed on the steering column. If the tape is removed before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-BAG 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 AIR-BAG 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/Service and Repair for the procedures. Fig. 43 Auto-locking clockspring 3. Depress the two plastic clockspring auto-locking tabs. 4. Keeping the auto-locking tabs depressed, rotate the clockspring hub clockwise to the end of its travel. Do not apply excessive torque. 5. From the end of the clockwise travel, rotate the hub about two and one-half turns counterclockwise, then release the auto-locking tabs. The clockspring horn wire harness should end up at the top, and the airbag, optional speed control and optional remote radio wire harnesses at the bottom. 6. The front wheels should still be in the straight ahead position. Install the clockspring onto the steering column. Refer to Clockspring/Service and Repair for the procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5477 Clockspring Assembly / Spiral Cable: Service and Repair The clockspring cannot be repaired. It must be replaced if faulty or damaged, or if the driver side airbag has been deployed. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-BAG 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 AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 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 side airbag module from the steering wheel. Refer to Driver Side Airbag Module Replacement for the procedures. 3. If the vehicle is so equipped, disconnect the upper clockspring wire harness connectors from the vehicle speed control switches and the remote radio switches located within the hub cavity of the steering wheel. 4. Remove the nut that secures the steering wheel armature to the steering column upper shaft, which is located within the hub cavity of the steering wheel. 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. Refer to Steering Column Opening Cover/Service and Repair of Instrument Panel Systems for the procedures. 7. If the vehicle is so equipped, unscrew the lever from the tilt steering column adjuster mechanism located on the left side of the column just below the multi-function switch stalk. Steering Column Shrouds Remove/Install - Typical 8. Remove both the upper and lower shrouds from the steering column. 9. Remove the lower fixed column shroud from the steering column. 10. Disconnect the instrument panel wire harness connector from the lower clockspring connector receptacle. 11. Disconnect the lower clockspring wire harness connector from the instrument panel wire harness, located on the instrument panel lower reinforcement below the steering column. 12. Carefully disengage the plastic latches of the clockspring assembly from the steering column lock housing and remove the clockspring from the column.The clockspring cannot be repaired. It must be replaced if faulty or damaged, or if the driver side airbag has been deployed. INSTALLATION 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 Centering in the Adjustments before installing or reinstalling a clockspring. Service replacement clocksprings are shipped precentered and with a piece of tape covering the depressed clockspring auto-locking tabs. This tape should not be removed until the clockspring has been installed on the steering column. If the tape is removed before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. 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 clockspring latches engage the steering column lock Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5478 housing. 2. Reconnect the lower clockspring wire harness connector to the instrument panel wire harness. Be certain that the wire harness locator clips are properly seated on the outside of the wiring trough and that the connector latches are fully engaged. 3. Reconnect the instrument panel wire harness connector to the lower clockspring connector receptacle. 4. Install the steering column shrouds. Be certain that the lower clockspring wire harness is routed inside the shrouds. 5. Install the steering column opening cover onto the instrument panel. Refer to Steering Column Opening Cover/Service and Repair of Instrument Panel Systems for the procedures. 6. Install the steering wheel onto the steering column upper shaft. Be certain to index the flats on the hub of the steering wheel with the formations on the inside of the clockspring hub. Pull the upper clock- spring wire harnesses through the upper and lower holes between the steering wheel back trim cover and the steering wheel armature. 7. Install and tighten the steering wheel mounting nut. Tighten the nut to 61 Nm (45 ft. lbs.). Be certain not to pinch the wire harnesses between the steering wheel and the nut. 8. If the vehicle is so equipped, reconnect the upper clockspring wire harness connectors to the vehicle speed control switches and/or the remote radio switches. Be certain that the upper clockspring wire harnesses are routed between the steering wheel back trim cover and the steering wheel armature. 9. If the vehicle is so equipped, install the tilt steering column lever to the steering column by screwing it into place. 10. Install the driver side airbag module onto the steering wheel. Refer to Driver Side Airbag Module Replacement for the procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Application and ID Malfunction Lamp / Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Airbag Lamp ........................................................................................................................................ ............................................................. PC194 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5486 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5487 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5488 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5489 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5490 TIME ALLOWANCE: FAILURE CODE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications ACM to Transmission Tunnel Bracket Mounting Screws (3) 105 in.lb Instrument Panel Wiring Harness Ground Eyelet to Transmission Tunnel Bracket Screw 30 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 5495 Air Bag Control Module: Locations Airbag Control Module Remove/Install The Airbag Control Module (ACM) is secured with screws to a mount welded onto the floor panel transmission tunnel behind the instrument panel center support bracket in the passenger compartment of the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 5496 Airbag Control Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 5497 Air Bag Control Module: Description and Operation DESCRIPTION The Airbag Control Module (ACM) is secured with screws to a mount welded onto 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 cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. OPERATION The microprocessor in the ACM contains the airbag system logic. The airbag system logic includes On-Board Diagnostics (OBD), and the ability to communicate with the instrument cluster circuitry over the Chrysler Collision Detection (CCD) data bus to control the airbag indicator lamp. The microprocessor continuously monitors all of the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster over the CCD data bus to turn on the airbag indicator lamp. Refer to Instrument Cluster in the Instrument Panel Systems for more information on the airbag indicator lamp. One electronic impact sensor is used in this airbag system. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. 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. In addition to the electronic impact sensor, there is an electromechanical sensor within the ACM called a safing sensor. The safing sensor is a normally open series switch located in the airbag deployment circuit of the ACM. This sensor detects impact energy of a lesser magnitude than the electronic impact sensor, and must be closed in order for the airbags to deploy The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the airbags for up to one second following a battery disconnect or failure during an impact. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact, if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 5498 Air Bag Control Module: Service and Repair WARNING: - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIR BAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR BAG 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 AIR-BAG 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 AIR BAG 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. REMOVAL 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 center support bracket from the instrument panel. Refer to Instrument Panel Center Support Bracket Replacement of Instrument Panel Systems for the procedures. Airbag Control Module Remove/Install 3. Remove the screw that secures the instrument panel wire harness ground eyelet to the left side of the mount that is welded onto the floor panel transmission tunnel. 4. Disconnect the instrument panel wire harness connector from the Airbag Control Module (ACM). To disconnect the instrument panel wire harness connector from the ACM: a. Slide the red Connector Position Assurance (CPA) lock on the top of the connector toward the side of the vehicle. b. Depress the connector latch tab and pull the connector straight away from the ACM connector receptacle. 5. Remove the three screws that secure the ACM to the mount that is welded onto the floor panel transmission tunnel. 6. Remove the ACM from the mount on the floor panel transmission tunnel. INSTALLATION 1. Carefully position the ACM to the mount that is welded onto the floor panel transmission tunnel. When the ACM is correctly positioned the arrow on the ACM label will be pointed forward in the vehicle. 2. Install and tighten the three screws that secure the ACM to the mount that is welded onto the floor panel transmission tunnel. Tighten the screws to 11.8 Nm (105 in. lbs.). 3. Install and tighten the screw that secures the instrument panel wire harness ground eyelet to the left side of the mount that is welded onto the floor panel transmission tunnel. Tighten the screw to 3.4 Nm (30 in. lbs.). 4. Reconnect the instrument panel wire harness connector to the ACM connector receptacle. Be certain that the connector latch and the red CPA lock are fully engaged. 5. Do not reconnect the battery negative cable at this time. Refer to Airbag System in the Diagnosis and Testing for the proper procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming Disconnect and isolate the battery negative cable. If the airbag module has not been deployed, wait two minutes for the system capacitor to discharge before further service. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 5504 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming 16-Way Data Link Connector - Typical 1. Make sure no one is in the vehicle. 2. Connect the negative battery terminal. 3. Connect the DRB scan tool to the 16-way data link wire harness connector. The connector is located on the driver side lower edge of the instrument panel, outboard of the steering column. 4. Turn the ignition switch to the ON position. Exit the vehicle with the DRB. Use the latest version of the proper DRB cartridge. 5. Erase the stored DTC data. If any problems remain, the stored DTC data will not erase. 6. With the ignition switch still in the ON position, make sure nobody is in the vehicle. 7. From outside of the vehicle (away from the airbag modules in case of an accidental deployment) turn the ignition switch to the OFF position for about 10 seconds, and then back to the ON position. Observe the airbag indicator lamp in the instrument cluster. It should light for six to 8 seconds, and then go out. This indicates that the airbag system is functioning normally. NOTE: If the airbag indicator lamp fails to light, or lights and stays on, there is an airbag system malfunction. Refer to the proper Diagnostic Procedures to diagnose the problem. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Tether Installation NUMBER: 23-029-08 GROUP: Body DATE: October 24, 2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. B, DATED NOVEMBER 24, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DEALERS PLEASE NOTE, THIS IS REIMBURSABLE REGARDLESS OF VEHICLE AGE OR MILEAGE. SUBJECT: Child Seat Tether Anchor Installation OVERVIEW: This bulletin describes procedures to install Child Seat Tether Anchors based on Customer Request. NOTE: Dealers are encouraged to honor any customers request for the installation of the Child Seat Tether Anchors and Dealer reimbursement will be made by Chrysler regardless of vehicle age or mileage. See the Warranty Policy and Procedure Manual and or Warranty Bulletin D-08-33 for reimbursement detail. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shawdow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5510 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year and later. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. Chrysler is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. NOTE: This bulletin is provided to identify the parts and labor operation numbers necessary to install a Child Seat Tether Anchor. Each dealer is encouraged to install these kits based on customer request and Chrysler will reimburse any Chrysler / Dodge / or Jeep dealer installing these kits regardless of vehicle age or mileage. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5511 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5512 PARTS REQUIRED: POLICY: Customer Satisfaction, Reimbursable regardless of mileage or age. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5513 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5514 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5515 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5516 Child Seat Tether Attachment: Technical Service Bulletins Child Seat Tether Anchor - Labor/Parts Identification NUMBER: 23-35-99 Rev. A GROUP: Body DATE: Oct. 1, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-35-99 DATED SEPTEMBER 3, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES IN SOME TIME ALLOWANCES. SUBJECT: Child Seat Tether Anchors NOTE: THIS BULLETIN DOES NOT APPLY TO DAIMLERCHRYSLER CANADA DEALERS. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) LeBaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2000 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light truck in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5517 detailed instruction sheet. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5518 PARTS REQUIRED: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5519 POLICY: Customer Satisfaction Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5520 TIME ALLOWANCE: Failure Code: CG - Customer Satisfaction Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5521 Child Seat Tether Attachment: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5522 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5523 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5524 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5525 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5526 TIME ALLOWANCE: FAILURE CODE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Service Precautions Seat Belt Buckle Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Service Precautions > Page 5530 Seat Belt Buckle Switch: Description and Operation SYSTEM DESCRIPTION The driver seat belt switch is integral to the driver seat belt retractor assembly. The driver seat belt switch is normally closed, providing a ground signal to the instrument cluster when the ignition switch is in the On or Start positions. The seat belt switch monitors the amount of 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 opens the seat belt switch sense circuit. The driver seat belt switch cannot be repaired and, if faulty or damaged, the entire driver seat belt and retractor unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Service Precautions > Page 5531 Seat Belt Buckle Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. Unplug the wire harness connector from the driver seat belt retractor. Check for continuity between the circuit cavity in the body half of the driver seat belt switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open circuit as required. 2. Check for continuity between the two cavities in the seat belt half of the driver seat belt switch wire harness 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 seat belt and retractor assembly. 3. Remove the instrument cluster from the instrument panel. Check for continuity between the seat belt switch sense circuit cavities of the instrument cluster wire harness connector (connector B) and the body half of the driver seat belt switch wire harness connector. There should be continuity. If OK, see Instrument Cluster in the Diagnosis and Testing for diagnosis of the chime request circuit. If not OK, repair the open circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement Technical Service Bulletin # 978 Date: 010801 Recall - Seat Belt Retractor Replacement August 2001 Dealer Service Instructions for: Safety Recall No. 978 -- Front Seat Belt Retractors Models 1999 (AB) Dodge Ram Van/Wagon NOTE: This recall applies only to the above vehicles built from December 18, 1998 through January 29, 1999 (MDH 1218XX through 0129XX) 1999 (AN) Dodge Dakota NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 15, 1999 (MDH 1206XX through 0115XX) 1999 (DN) Dodge Durango NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 18, 1999 (MDH 1206XX through 0118XX) 1999 (LH) Chrysler Concorde, LHS and 300M and Dodge Intrepid NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 19, 1999 (MDH 1206XX through 0119XX) 1999 (NS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth Voyager/Grand Voyager NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 19, 1999 (MDH 1206XX through 0119XX) 1999 (WJ) Jeep Grand Cherokee NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 19, 1999 (MDH 1206XX through 0119XX) 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 DIAL VIP System. Subject One or both of the front seat belt retractor assemblies on about 150,000 of the above vehicles may not comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) 209. An improperly manufactured internal lever may not lock the seat belt retractor. This could allow increased risk of injury to a front seat occupant in certain accident conditions. Repair The front seat belt retractor assembly(s) must be replaced. Parts Information No parts will be distributed initially for this recall. Dealers should determine which Seat Belt Retractor package is required for each vehicle at the time appointments are scheduled to assure that the correct parts are available when the customer arrives. Each package contains a right and a left front seat belt retractor (except as noted) . The retractor package for the vehicle to be serviced may be determined by: ^ Using the part code in the third column of the VIN list along with the table (involved dealers); ^ Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement > Page 5540 ^ Entering the VIN into the DIAL VIP System (sales code information) along with the table (all dealers) shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Parts Return Not required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement > Page 5541 Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by firs class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer injury as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD978". 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. 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 Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. AB Vans/Wagons IMPORTANT: Ram Vans/Wagons equipped with a sliding door require right (passenger side) front seat belt retractor assembly replacement only. 1. Open the passenger side doors. 2. Using a small flat blade, pry the turning loop cover open. 3. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster. 4. Remove the retractor/seat belt lower anchor bolt from the front seat riser. 5. Remove and discard the retractor assembly. 6. Install the new retractor assembly. 7. Install the retractor/seat belt anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 8. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 9. Close the turning loop cover. 10. For vehicles equipped with dual hinged side doors, repeat Steps 1-9 for the driver's side of the vehicle. AN Trucks IMPORTANT: Dakota trucks require left (driver side) front seat belt retractor assembly replacement only. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement > Page 5542 1. Open the driver's side door. 2. Remove the driver's door sill plate. 3. For Club Cab trucks, remove the cab back trim panel. 4. Using a small flat blade, pry the front seat belt turning loop cover open. 5. Remove the front seat belt turning loop attaching bolt and disconnect the turning loop from the height adjuster. 6. For Club Cab trucks, pry the rear seat belt turning loop cover open using a small flat blade. 7. For Club Cab trucks, remove the rear seat belt turning loop attaching bolt and disconnect the turning loop from the height adjuster. 8. Remove the quarter (B-Pillar) trim panel. 9. Remove the lower seat belt anchor bolt. 10. Remove the anchor bolt that attaches the retractor to the B-pillar. 11. Disconnect the retractor electrical connector (if equipped). 12. Remove and discard the retractor assembly. 13. Install the new retractor assembly. 14. Install the retractor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). 15. Connect the retractor electrical connector (if equipped). 16. Install the lower seat belt anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). 17. Install the quarter (B-pillar) trim panel. 18. For Club Cab trucks, install the rear seat belt turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). 19. Install the front seat belt turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). 20. Close the turning loop cover(s). 21. For Club Cab trucks, install the cab back trim panel. 22. Install the door sill plate. DN Vehicles 1. Open the driver's door. 2. Using a small flat blade, pry the turning loop cover open. 3. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster. 4. Remove the lower seat belt anchor bolt from the driver's seat. 5. Remove the driver's door sill plate. 6. Remove the upper B-Pillar trim panel. 7. Remove the lower B-Pillar trim panel. 8. Disconnect the retractor electrical connector. 9. Remove the anchor bolt that attaches the retractor to the B-pillar. 10. Remove and discard the retractor assembly. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement > Page 5543 11. Remove the anti-rotation tab from the new retractor assembly and then install the new retractor assembly. 12. Install the retractor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 13. Connect the retractor electrical connector. 14. Install the lower B-pillar trim panel. 15. Install the upper B-pillar trim panel. 16. Install the driver's door sill plate. 17. Install the lower seat belt anchor bolt (Figure 3). Tighten the bolt to 17 ft-lbs (23 Nm) 18. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 19. Close the turning loop cover. 20. Repeat Steps 1-19 for the passenger side of the vehicle. LH Vehicles 1. Using a small flat blade, pry the turning loop cover open. 2. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster. 3. Remove the seat belt/retractor lower anchor bolt. 4. Remove the upper B-Pillar trim panel. 5. Remove the lower B-Pillar trim panel. 6. Remove and discard the retractor assembly. 7. Install the new retractor assembly. 8. Install the lower B-pillar trim panel. 9. Install the upper B-pillar trim panel. 10. Install the seat belt/retractor lower anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 11. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 12. Close the turning loop cover. 13. Repeat Steps 1-12 for the other side of the vehicle. WJ Vehicles 1. Open the driver's door. 2. Using a small flat blade, pry the turning loop cover open. 3. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster. 4. Remove the lower seat belt anchor bolt. 5. Remove the driver's door sill plate. 6. Remove the lower B-Pillar trim panel. 7. Remove and discard the retractor assembly. 8. Install the new retractor assembly. 9. Install the lower B-pillar trim panel. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement > Page 5544 10. Install the driver's door sill plate. 11. Install the lower seat belt anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 12. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 13. Close the turning loop cover. 14. Repeat Steps 1-13 for the passenger side of the vehicle. NS Minivans IMPORTANT: Town & Country minivans equipped with a taupe-colored leather interior require left (driver side) front seat belt retractor assembly replacement only. 1. Using a small flat blade, pry the turning loop cover open. 2. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster. 3. Remove the upper B-Pillar trim panel. 4. Remove the seat belt floor anchor bolt. 5. Remove the lower B-Pillar trim panel. (On three door models, remove the upper bolster from the left quarter trim panel, remove the five screws across the top and three screws at the front of the trim panel and then pull the front of the quarter trim panel back far enough to access the retractor assembly.) 6. Remove the anchor bolt that attaches the retractor to the B-pillar. 7. Disconnect the retractor electrical connector, if equipped, and then remove and discard the retractor assembly. 8. Connect the retractor electrical connector, if equipped, and then install the new retractor assembly. 9. Install the retractor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 10. Install the lower B-pillar trim panel (or left quarter trim panel on three door models). 11. Install the seat belt floor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). Make sure that the floor anchor is properly oriented (30 outboard). 12. Install the upper B-pillar trim panel. 13. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 14. Close the turning loop cover. 15. Repeat Steps 1-14 for the other side of the vehicle if necessary. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > NHTSA01V119000 > Apr > 01 > Recall 01V119000: Seat Belt Retractor Seat Belt Retractor: Recalls Recall 01V119000: Seat Belt Retractor Vehicle Description: Certain van, wagon, pickup trucks, passenger and sport utility vehicles, fail to comply with requirements of FMVSS No. 209, "Seat Belt Assemblies." The front seat belt retractor may not comply with the requirements of the standard. If the retractor does not work properly, it will not adequately protect occupants in the event of a crash. Dealers will replace the seat belt retractor. DaimlerChrysler has not yet provided NHTSA with an owner notification schedule for this campaign. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair Front Steering Knuckle: Technical Service Bulletins Front Caliper Mounting/Steering Knuckle Thread Repair NUMBER: 05-03-99 GROUP: Brakes EFFECTIVE DATE: Apr. 23, 1999 SUBJECT: Front Brake Caliper Mounting To Steering Knuckle Thread Repair OVERVIEW: This bulletin involves repair of the threads on the steering knuckle or brake caliper mounting adapter that are used to install and retain the front brake caliper housing in its correct operating location. MODELS: 1986 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango DISCUSSION: A Brake Knuckle Thread Repair Kit has been developed to repair stripped threads on the front brake caliper mounting attachment making it no longer necessary to replace the front steering knuckle/brake caliper mounting adapter when encountering stripped threads. The following information provides the repair procedure for using the Brake Knuckle Thread Repair Kit. DIAGNOSIS: 1. Place the vehicle on an appropriate hoist. 2. Remove the front tire/wheel assembly. 3. Remove the brake caliper housing assembly by loosening the mounting bolts. NOTE: IF HIGH TORQUE IS ENCOUNTERED DURING THE MOUNTING BOLT REMOVAL, IT IS LIKELY THAT THREAD DAMAGE WILL OCCUR OR HAS OCCURRED. 4. Remove the caliper housing assembly and hang the housing on the frame of the vehicle using an appropriate wire hanger. NOTE: DO NOT ALLOW THE CALIPER HOUSING TO HANG BY ITSELF FROM THE BRAKE HOSE AS DAMAGE TO THE HOSE MAY RESULT. 5. If the vehicle has a bolt-on brake caliper mounting adapter, remove the adapter. If the brake caliper mounts directly to the steering knuckle, remove retainers on the wheel studs and remove the rotor. 6. Inspect the mounting bolts and knuckle threads for damage. If either is damaged, it is likely that damage to the other has occurred as well. If damage has occurred to the threads in the form of knicks, thread pulling, or cross-threading, perform the Repair Procedure. PARTS REQUIRED: AR (1) 05016156AA Insert, Heli-Coil, M9 X 1.25 AR (1) 04886075AA Bolts, Caliper Housing Mounting EQUIPMENT REQUIRED: AR (1) 05016155AA Kit, Brake Knuckle Thread Repair Includes: 23/64 Drill Bit M9 X 1.25 Tap Heli-Coil Installation Tool Heli-Coil Tang Break-Off Rod (25) M9 X 1.25 Stainless Steel Heli-Coils REPAIR PROCEDURE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair > Page 5552 1. Using the 23/64 in. drill, drill through the brake caliper mounting attachment hole keeping the drill perpendicular to the knuckle. 2. Using the M9 X 1.25 tap, tap the drilled hole ensuring to tap the hole entirely through. 3. Install a Heli-Coil insert onto the installation tool (tool number 3747-9). Be sure the tang is properly engaged into the driving contour of the tool. 4. Install the Heli-Coil into the drilled/tapped hole by rotating the tool and exerting slight pressure onto the tool/Heli-Coil and into the drilled/tapped hole. Continue to rotate the tool until the insert is located 1/4 to 1/2 turn below the steering knuckle surface. 5. Back the Heli-Coil installation tool out of the installed Heli-Coil. Then, remove the tang from the Heli-Coil by breaking the tang off using the tang break-off tool. Place the break-off tool into the assembled insert until it rests on the Heli-Coil tang. Holding the tool squarely, strike the tool sharply with a hammer. 6. If the vehicle has a bolt-on brake caliper mounting adapter, install the adapter. Refer to the appropriate Service Manual for information regarding proper brake caliper adapter mounting information. If the brake caliper mounts directly to the steering knuckle, install the rotor. 7. Install the caliper using new mounting bolts p/n 04886075AA in any location that had a Heli-Coil installed. Tighten the bolts to 30 - 35 N.m (22-26 ft. lbs.). 8. Install the tire/wheel assembly. 9. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-93 Brake Caliper Mounting Support Thread Repair, Left Side 0.4 Hrs. 05-80-20-94 Brake Caliper Mounting Support Thread Repair, Right Side 0.4 Hrs. 05-80-20-50 Brake Caliper Mounting Support Thread Repair, Each Additional Same Side 0.1 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Page 5553 Front Steering Knuckle: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper, rotor, shield and ABS wheel speed sensor if equipped. 4. Remove front driveshaft. Tie Rod End 5. Remove tie rod end cotter pin and nut. Separate the tie rod from the knuckle with Remover MB-991113. 6. Support the lower suspension arm with a hydraulic jack and raise the jack to unload the rebound bumper. Upper Ball Joint 7. Remove the upper ball joint cotter pin and nut. Separate the ball joint from the knuckle with Remover MB-991113. CAUTION: When installing Remover MB-991113 to separate the ball joint, be careful not to damage the ball joint seal. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Page 5554 Lower Ball Joint 8. Remove the lower ball joint cotter pin and nut. Separate the ball joint from the knuckle with Remover C-4150A and remove the knuckle. 9. Remove the hub/bearing from the steering knuckle. INSTALLATION 1. Install the hub/bearing to the steering knuckle and tighten the bolts to 166 Nm (123 ft. lbs.). NOTE: When installing hub/bearing with ABS brakes, position the speed sensor opening towards the front of the vehicle. 2. Install the knuckle onto the upper and lower ball joint. CAUTION: The ball joint stud tapers must be CLEAN and DRY before installing the knuckle. Clean the stud tapers with mineral spirits to remove dirt and grease. 3. Install the upper and lower ball joint nuts. Tighten the upper ball joint nut to 81 Nm (60 ft. lbs.) and the lower ball joint nut to 183 Nm (135 ft. lbs.) then install cotter pins. Grease the lower ball joint. 4. Remove the hydraulic jack from the lower suspension arm. 5. Install the tie rod end and tighten the nut to 88 Nm (65 ft. lbs.). Install the cotter pin. 6. Install the front driveshaft. 7. Install the ABS wheel speed sensor if equipped and brake shield, rotor and caliper. 8. Install the wheel and tire assembly. 9. Remove support and lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 21-08-99 > Apr > 99 > Recalls for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement Technical Service Bulletin # 978 Date: 010801 Recall - Seat Belt Retractor Replacement August 2001 Dealer Service Instructions for: Safety Recall No. 978 -- Front Seat Belt Retractors Models 1999 (AB) Dodge Ram Van/Wagon NOTE: This recall applies only to the above vehicles built from December 18, 1998 through January 29, 1999 (MDH 1218XX through 0129XX) 1999 (AN) Dodge Dakota NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 15, 1999 (MDH 1206XX through 0115XX) 1999 (DN) Dodge Durango NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 18, 1999 (MDH 1206XX through 0118XX) 1999 (LH) Chrysler Concorde, LHS and 300M and Dodge Intrepid NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 19, 1999 (MDH 1206XX through 0119XX) 1999 (NS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth Voyager/Grand Voyager NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 19, 1999 (MDH 1206XX through 0119XX) 1999 (WJ) Jeep Grand Cherokee NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 19, 1999 (MDH 1206XX through 0119XX) 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 DIAL VIP System. Subject One or both of the front seat belt retractor assemblies on about 150,000 of the above vehicles may not comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) 209. An improperly manufactured internal lever may not lock the seat belt retractor. This could allow increased risk of injury to a front seat occupant in certain accident conditions. Repair The front seat belt retractor assembly(s) must be replaced. Parts Information No parts will be distributed initially for this recall. Dealers should determine which Seat Belt Retractor package is required for each vehicle at the time appointments are scheduled to assure that the correct parts are available when the customer arrives. Each package contains a right and a left front seat belt retractor (except as noted) . The retractor package for the vehicle to be serviced may be determined by: ^ Using the part code in the third column of the VIN list along with the table (involved dealers); ^ Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 21-08-99 > Apr > 99 > Recalls for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement > Page 5564 ^ Entering the VIN into the DIAL VIP System (sales code information) along with the table (all dealers) shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Parts Return Not required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 21-08-99 > Apr > 99 > Recalls for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement > Page 5565 Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by firs class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer injury as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD978". 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. 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 Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. AB Vans/Wagons IMPORTANT: Ram Vans/Wagons equipped with a sliding door require right (passenger side) front seat belt retractor assembly replacement only. 1. Open the passenger side doors. 2. Using a small flat blade, pry the turning loop cover open. 3. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster. 4. Remove the retractor/seat belt lower anchor bolt from the front seat riser. 5. Remove and discard the retractor assembly. 6. Install the new retractor assembly. 7. Install the retractor/seat belt anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 8. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 9. Close the turning loop cover. 10. For vehicles equipped with dual hinged side doors, repeat Steps 1-9 for the driver's side of the vehicle. AN Trucks IMPORTANT: Dakota trucks require left (driver side) front seat belt retractor assembly replacement only. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 21-08-99 > Apr > 99 > Recalls for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement > Page 5566 1. Open the driver's side door. 2. Remove the driver's door sill plate. 3. For Club Cab trucks, remove the cab back trim panel. 4. Using a small flat blade, pry the front seat belt turning loop cover open. 5. Remove the front seat belt turning loop attaching bolt and disconnect the turning loop from the height adjuster. 6. For Club Cab trucks, pry the rear seat belt turning loop cover open using a small flat blade. 7. For Club Cab trucks, remove the rear seat belt turning loop attaching bolt and disconnect the turning loop from the height adjuster. 8. Remove the quarter (B-Pillar) trim panel. 9. Remove the lower seat belt anchor bolt. 10. Remove the anchor bolt that attaches the retractor to the B-pillar. 11. Disconnect the retractor electrical connector (if equipped). 12. Remove and discard the retractor assembly. 13. Install the new retractor assembly. 14. Install the retractor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). 15. Connect the retractor electrical connector (if equipped). 16. Install the lower seat belt anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). 17. Install the quarter (B-pillar) trim panel. 18. For Club Cab trucks, install the rear seat belt turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). 19. Install the front seat belt turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). 20. Close the turning loop cover(s). 21. For Club Cab trucks, install the cab back trim panel. 22. Install the door sill plate. DN Vehicles 1. Open the driver's door. 2. Using a small flat blade, pry the turning loop cover open. 3. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster. 4. Remove the lower seat belt anchor bolt from the driver's seat. 5. Remove the driver's door sill plate. 6. Remove the upper B-Pillar trim panel. 7. Remove the lower B-Pillar trim panel. 8. Disconnect the retractor electrical connector. 9. Remove the anchor bolt that attaches the retractor to the B-pillar. 10. Remove and discard the retractor assembly. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 21-08-99 > Apr > 99 > Recalls for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement > Page 5567 11. Remove the anti-rotation tab from the new retractor assembly and then install the new retractor assembly. 12. Install the retractor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 13. Connect the retractor electrical connector. 14. Install the lower B-pillar trim panel. 15. Install the upper B-pillar trim panel. 16. Install the driver's door sill plate. 17. Install the lower seat belt anchor bolt (Figure 3). Tighten the bolt to 17 ft-lbs (23 Nm) 18. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 19. Close the turning loop cover. 20. Repeat Steps 1-19 for the passenger side of the vehicle. LH Vehicles 1. Using a small flat blade, pry the turning loop cover open. 2. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster. 3. Remove the seat belt/retractor lower anchor bolt. 4. Remove the upper B-Pillar trim panel. 5. Remove the lower B-Pillar trim panel. 6. Remove and discard the retractor assembly. 7. Install the new retractor assembly. 8. Install the lower B-pillar trim panel. 9. Install the upper B-pillar trim panel. 10. Install the seat belt/retractor lower anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 11. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 12. Close the turning loop cover. 13. Repeat Steps 1-12 for the other side of the vehicle. WJ Vehicles 1. Open the driver's door. 2. Using a small flat blade, pry the turning loop cover open. 3. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster. 4. Remove the lower seat belt anchor bolt. 5. Remove the driver's door sill plate. 6. Remove the lower B-Pillar trim panel. 7. Remove and discard the retractor assembly. 8. Install the new retractor assembly. 9. Install the lower B-pillar trim panel. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 21-08-99 > Apr > 99 > Recalls for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement > Page 5568 10. Install the driver's door sill plate. 11. Install the lower seat belt anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 12. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 13. Close the turning loop cover. 14. Repeat Steps 1-13 for the passenger side of the vehicle. NS Minivans IMPORTANT: Town & Country minivans equipped with a taupe-colored leather interior require left (driver side) front seat belt retractor assembly replacement only. 1. Using a small flat blade, pry the turning loop cover open. 2. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster. 3. Remove the upper B-Pillar trim panel. 4. Remove the seat belt floor anchor bolt. 5. Remove the lower B-Pillar trim panel. (On three door models, remove the upper bolster from the left quarter trim panel, remove the five screws across the top and three screws at the front of the trim panel and then pull the front of the quarter trim panel back far enough to access the retractor assembly.) 6. Remove the anchor bolt that attaches the retractor to the B-pillar. 7. Disconnect the retractor electrical connector, if equipped, and then remove and discard the retractor assembly. 8. Connect the retractor electrical connector, if equipped, and then install the new retractor assembly. 9. Install the retractor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 10. Install the lower B-pillar trim panel (or left quarter trim panel on three door models). 11. Install the seat belt floor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). Make sure that the floor anchor is properly oriented (30 outboard). 12. Install the upper B-pillar trim panel. 13. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm) 14. Close the turning loop cover. 15. Repeat Steps 1-14 for the other side of the vehicle if necessary. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 21-08-99 > Apr > 99 > Recalls for Seat Belt Retractor: > NHTSA01V119000 > Apr > 01 > Recall 01V119000: Seat Belt Retractor Seat Belt Retractor: Recalls Recall 01V119000: Seat Belt Retractor Vehicle Description: Certain van, wagon, pickup trucks, passenger and sport utility vehicles, fail to comply with requirements of FMVSS No. 209, "Seat Belt Assemblies." The front seat belt retractor may not comply with the requirements of the standard. If the retractor does not work properly, it will not adequately protect occupants in the event of a crash. Dealers will replace the seat belt retractor. DaimlerChrysler has not yet provided NHTSA with an owner notification schedule for this campaign. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5578 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5579 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5580 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5581 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5582 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5583 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5584 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5585 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5586 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5587 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5588 PARTS REQUIRED: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5589 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5590 POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Page 5591 Passenger Airbag On/Off Switch C1 (Switch Side) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Service Precautions Seat Belt Buckle Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Service Precautions > Page 5595 Seat Belt Buckle Switch: Description and Operation SYSTEM DESCRIPTION The driver seat belt switch is integral to the driver seat belt retractor assembly. The driver seat belt switch is normally closed, providing a ground signal to the instrument cluster when the ignition switch is in the On or Start positions. The seat belt switch monitors the amount of 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 opens the seat belt switch sense circuit. The driver seat belt switch cannot be repaired and, if faulty or damaged, the entire driver seat belt and retractor unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Service Precautions > Page 5596 Seat Belt Buckle Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. Unplug the wire harness connector from the driver seat belt retractor. Check for continuity between the circuit cavity in the body half of the driver seat belt switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open circuit as required. 2. Check for continuity between the two cavities in the seat belt half of the driver seat belt switch wire harness 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 seat belt and retractor assembly. 3. Remove the instrument cluster from the instrument panel. Check for continuity between the seat belt switch sense circuit cavities of the instrument cluster wire harness connector (connector B) and the body half of the driver seat belt switch wire harness connector. There should be continuity. If OK, see Instrument Cluster in the Diagnosis and Testing for diagnosis of the chime request circuit. If not OK, repair the open circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications Antenna: Specifications Antenna Cap Nut 70 in.lb Antenna Mast to Antenna Body 30 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications > Page 5601 Antenna Mounting Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications > Page 5602 Antenna: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications > Page 5603 Antenna: Description and Operation DESCRIPTION All models use a fixed-length stainless steel rodtype 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 inboard 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications > Page 5604 Antenna: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG 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. NOTE: 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 inboard 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications > Page 5605 Test 4 checks the condition of the ground between the antenna base and the vehicle body as follows: 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications > Page 5606 Antenna: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO 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 AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 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. Antenna Cable Routing 3. Reach under the instrument panel below the glove box to access and disconnect the antenna coaxial cable connector. Disconnect the connector by pulling it apart while twisting the metal connector harness. Do not pull on the cable. 4. Disengage the antenna coaxial cable from the retainer clips on the lower instrument panel reinforcement and the heater-A/C housing. 5. Disengage the antenna coaxial cable retainers at the right cowl side inner panel and inside the right front fender. Antenna Mast Remove/Install - Typical 6. Unscrew the antenna mast from the antenna body. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications > Page 5607 Antenna Cap Nut Remove/Install - Typical 7. Remove the antenna cap nut using an antenna nut wrench (Special Tool C-4816). 8. Remove the antenna adapter from the top of the fender. 9. Lower the antenna body through the mounting hole in the top of the fender. Antenna Mounting 10. 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. 11. Disengage the antenna coaxial cable grommet from the hole in the right cowl side outer panel. 12. Pull the antenna coaxial cable out of the passenger compartment through the hole in the right cowl side outer panel. 13. Remove the antenna body and cable from the vehicle. Instrument Panel Antenna Cable 1. Disconnect and isolate the battery negative cable. 2. Reach under the instrument panel below 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 clip on the lower instrument panel reinforcement inboard of the glove box opening. 5. Roll down the glove box from the instrument panel. Refer to Glove Box/Service and Repair of Instrument Panel Systems for the procedures. 6. Reach through the glove box opening to access and disengage the retainer that secures the antenna cable to the instrument panel structural support on the inboard side of the glove box opening. 7. Remove the radio receiver from the instrument panel. Refer to Radio Receiver/Service and Repair for the procedures. 8. Pull the antenna cable out through the radio receiver opening in the instrument panel. 9. 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications > Page 5608 panel. 10. 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 reinforcement and the heater-A/C housing. 10. Reach under the instrument panel below 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. The 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 Radio Receiver/Service and Repair for the procedures. 4. Reach through the glove box opening to access and engage the retainer that secures the antenna cable to the instrument panel structural support on the inboard side of the glove box opening. 5. Install the glove box onto the instrument panel. Refer to Glove Box/Service and Repair of Instrument Panel Systems for the procedures. 6. Engage the instrument panel antenna cable to the retainer clip on the lower instrument panel reinforcement inboard of the glove box opening. 7. Untie the cord or twine from the instrument panel half of the antenna coaxial cable connector. 8. Reach under the instrument panel below the glove box to access and reconnect the antenna coaxial cable connector. 9. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications > Page 5609 Antenna Nut Wrench C-4816 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Arm/Disarm Switch, Antitheft > Component Information > Diagrams Arm/Disarm Switch: Diagrams Driver Door Arm/Disarm Switch Driver Door Arm/Disarm Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch (For Alarm) > Component Information > Description and Operation Door Sensor/Switch (For Alarm): Description and Operation SYSTEM 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch (For Alarm) > Component Information > Description and Operation > Page 5617 Door Sensor/Switch (For Alarm): Service and Repair REMOVAL AND INSTALLATION The door ajar switch is integral to the door latch unit. If the door ajar switch is faulty or damaged, the entire door latch unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Description and Operation Keyless Entry Receiver: Description and Operation SYSTEM OPERATION The Remote Keyless Entry (RKE) receiver is a radio frequency unit that is integral to the high-line version of the Central Timer Module (CTM). The CTM also contains the program logic and control circuitry for the RKE system. The CTM is mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. The RKE receiver has a memory function to retain the vehicle access codes of up to four RKE transmitters. The receiver is designed to retain the transmitter codes in memory, even if the battery is disconnected. The RKE receiver is energized by one of three radio frequency inputs from the RKE transmitter; Unlock, Lock, or Panic. The programming of the CTM responds to these RKE inputs, as well as many other inputs, by sending the proper control outputs to the power lock motors, the courtesy lamp circuit, the driver unlock relay, the horn relay, and the headlamp relay For diagnosis or programming of the RKE receiver within the high-line CTM, a DRB scan tool and the proper Diagnostic Procedures are recommended. The RKE receiver is only serviced as a unit with the high-line CTM and, if faulty or damaged, the CTM unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 another suitable wide flat-bladed tool, gently pry at the center seam of the transmitter case halves near the key ring until the two halves unsnap. 2. Lift the back half of the transmitter case off of the transmitter. 3. Remove the two batteries from the 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 transmitter case halves with each other, and squeeze them firmly together until they snap back into place. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations Lock Cylinder Switch: Locations Door Lock Cylinder Switch Remove/Install - Typical Liftgate Lock Cylinder Switch Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Page 5629 Lock Cylinder Switch: Description and Operation SYSTEM DESCRIPTION Door Lock Cylinder Switch The door lock cylinder switches are mounted to the back of the key lock cylinder inside each front door. They are normally-open momentary switches that close to ground only when the lock cylinder is rotated to the unlock position. The door lock cylinder switches cannot be repaired and, if faulty or damaged, they must be replaced. Liftgate Lock Cylinder Switch The liftgate lock cylinder switch is mounted to the back of the key lock cylinder inside the liftgate. It is a normally-open momentary switch that closes to ground only when the lock cylinder is rotated to the unlock position. The liftgate lock cylinder switch cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Page 5630 Lock Cylinder Switch: Service and Repair REMOVAL AND INSTALLATION Door Lock Cylinder Switch 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 far enough to access the door lock cylinder switch. 4. Disengage the door lock cylinder switch from the back of the lock cylinder. 5. Unplug the door lock cylinder switch wire harness connector. 6. Disengage the retainers that secure the door lock cylinder switch wire harness to the inner door panel. 7. Remove the door lock cylinder switch from the door. 8. Reverse the removal procedures to install. Liftgate Lock Cylinder Switch 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 disengage the switch from the back of the liftgate lock cylinder. 4. Unplug the liftgate lock cylinder switch wire harness connector. 5. Remove the liftgate lock cylinder switch from the liftgate. 6. Reverse the removal procedures to install. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Locations Security Lamp/Indicator: Locations The security lamp is located within the instrument cluster on the instrument panel. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Locations > Page 5634 Security Lamp/Indicator: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Locations > Page 5635 Security Lamp/Indicator: Description and Operation SYSTEM DESCRIPTION The security lamp is located within the instrument cluster on the instrument panel. The security lamp is illuminated by a red Light-Emitting Diode (LED) that is integral to the instrument cluster circuit board. The security lamp receives fused battery feed at all times and is grounded by the high-line Central Timer Module (CTM) to give a visual indication of the Vehicle Theft Security System (VTSS) arming status. The security lamp cannot be repaired and, if faulty or damaged, the instrument cluster unit must be replaced. Refer to Instrument Cluster Replacement of Instrument Panel Systems for the service procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Locations > Page 5636 Security Lamp/Indicator: Testing and Inspection HARD-WIRED LAMP DIAGNOSIS This lamp depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedure will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS (SUPPLEMENTAL 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. SECURITY LAMP The diagnosis found here addresses an inoperative security lamp condition. If the problem being diagnosed is an inaccurate security lamp, refer to testing of the Vehicle Theft Security System in Body Control Module Testing and Inspection. See: Body and Frame/Body Control Systems/Central Timer Module/Testing and Inspection For complete circuit diagrams, refer to Complete Body and Chassis Diagrams See: Diagrams/Electrical Diagrams/Diagrams By Group Number 1. Check the fused B(+) 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. Check for battery voltage at the fused B(+) fuse in the junction block. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit to the battery as required. 3. Disconnect and isolate the battery negative cable. Remove the Central Timer Module (CTM). Disconnect the CTM wire harness connectors. Connect the battery negative cable. Install a jumper wire between the VTSS indicator driver circuit cavity of the 18-way CTM wire harness connector and a good ground. The security lamp should light. If OK, use a DRB scan tool and the proper Diagnostic Procedures manual to diagnose the Vehicle Theft Security System (VTSS) and the CTM. If not OK, go to Step 4. 4. Disconnect and isolate the battery negative cable. Remove the instrument cluster. Check for continuity between the fused B(+) circuit cavity of the instrument cluster wire harness connector A and the fused B(+) fuse in the junction block. There should be continuity. If OK, go to Step 5. If not OK, repair the open fused B(+) circuit to the junction block fuse as required. 5. Check for continuity between the VTSS indicator driver circuit cavities of the instrument cluster wire harness connector A and the 18-way CTM wire harness connector. There should be continuity. If OK, refer to Instrument Cluster Self-Diagnostic Test in the Diagnosis and Testing section of this group for further diagnosis of the security lamp and the instrument cluster circuitry. If not OK, repair the open VTSS indicator driver circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Description and Operation Trunk/Liftgate Sensor/Switch (For Alarm): Description and Operation SYSTEM DESCRIPTION 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Description and Operation > Page 5640 Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair The liftgate ajar switch is integral to the liftgate latch unit. If the liftgate ajar switch is faulty or damaged, the entire liftgate latch unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5645 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5646 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5647 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5652 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5653 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5654 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Specifications Garage Door Opener Transmitter: Specifications Tighten the two screws that secure the garage door opener storage bin door pivot and bumper block to the overhead console housing to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Specifications > Page 5658 Garage Door Opener Transmitter: Description and Operation GARAGE DOOR OPENER STORAGE BIN Description A compartment near the rear of the overhead console is designed to hold most garage door opener remote control transmitters. The door for the garage door opener compartment features a spring-loaded latch mechanism and has a small depression with tactile ribs just forward of the latch. The transmitter is mounted within the compartment with an adhesive-backed hook and loop fastener patch and, when the compartment is closed, the depressed area of the compartment door is pressed upward to actuate the transmitter. A transmitter mounting kit including the adhesive backed hook and loop fastener material and additional adapter pegs is available for service. The garage door opener storage bin door is also available for service replacement. The door unit includes the spring-loaded latch mechanism. If any of these components is damaged or faulty, the garage door opener storage bin door unit must be replaced. Operation The garage door opener storage compartment door is opened by pressing the spring-loaded latch towards the front of the vehicle. When the compartment door is opened, the garage door opener transmitter can be installed in the compartment using the adhesive backed hook and loop fastener material provided. With the transmitter mounted in the storage bin, adapter pegs located on the inside of the garage door opener door are selected and mounted on one of several posts on the back side of the door. The adapter pegs can be stacked if additional length is required. The combination of the adapter peg length and the peg location selected must be suitable to depress the button of the transmitter when the center of the garage door opener storage bin door is depressed. When the proper combination has been selected, the compartment door is closed and need not be reopened except to replace the transmitter batteries. See the owner's manual in the vehicle glove box for more information on the use and operation of the overhead console garage door opener storage bin. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Specifications > Page 5659 Garage Door Opener Transmitter: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console from the headliner. Refer to Overhead Console/Service and Repair for the procedures. Garage Door Opener Storage Bin Door Remove/Install 3. Remove the two screws that secure the garage door opener storage bin door pivot and bumper block to the overhead console housing. 4. Remove the garage door opener storage bin door pivot and bumper block from the overhead console housing. 5. Unlatch and remove the garage door opener storage bin door from the overhead console housing. INSTALLATION 1. Position the garage door opener storage bin door into the overhead console housing. 2. Engage the latch of the garage door opener storage bin door with the latch striker on the rear of the storage bin opening in the overhead console housing. 3. Be certain that both garage door opener storage bin door pivot pins are located in the two pivot receptacles in the overhead console housing just behind the sunglasses storage bin. 4. Position the garage door opener storage bin door pivot and bumper block onto the overhead console housing. 5. Install and tighten the two screws that secure the garage door opener storage bin door pivot and bumper block to the overhead console housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 6. Install the overhead console onto the headliner. Refer to Overhead Console/Service and Repair for the procedures. 7. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Specifications Amplifier: Specifications Tighten the screws right cowl side inner panel to 2 Nm (17 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Specifications > Page 5664 Power Amplifier Connections Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Specifications > Page 5665 Amplifier: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Specifications > Page 5666 Amplifier: Description and Operation DESCRIPTION Models equipped with the Infinity premium speaker package have a separate power amplifier unit. This power amplifier is rated at 100 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 in the Diagnosis and Testing. The power amplifier cannot be repaired or adjusted and, if faulty or damaged, the unit must be replaced. OPERATION The power amplifier is energized by a fused 12 volt output 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Specifications > Page 5667 Amplifier: Testing and Inspection 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 in the Diagnosis and Testing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Specifications > Page 5668 Amplifier: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the trim cover from the right cowl side inner panel. Refer to Cowl Trim Cover/Service and Repair of Body for the procedures. Power Amplifier Connections Remove/Install 3. Disconnect the two instrument panel wire harness connectors from the connector receptacles on the bottom of the power amplifier. Power Amplifier Remove/Install 4. Remove the two screws that secure the power amplifier to the right cowl side inner panel. 5. To disengage the upper hook bracket of the power amplifier from the upper hinge access hole in the right cowl side inner panel: a. Lift the power amplifier upwards about 5 centimeters (2 inches). b. Tilt the top of the power amplifier toward the instrument panel. c. Keep the top of the power amplifier tilted toward the instrument panel while lowering the unit from between the right cowl side inner panel and the end of the heater-A/C housing. 6. Remove the power amplifier from the right cowl side inner panel. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Specifications > Page 5669 INSTALLATION 1. Position the power amplifier to the right cowl side inner panel. 2. To engage the upper hook bracket of the power amplifier in the upper hinge access hole in the right cowl side inner panel: a. Tilt the top of the power amplifier toward the instrument panel. b. Keep the top of the power amplifier tilted toward the instrument panel while lifting the unit up between the right cowl side inner panel and the end of the heater-A/C housing. c. When the lower power amplifier mounting brackets are about 5 centimeters (2 inches) above the mounting holes for the lower brackets in the right cowl side inner panel, tilt the top of the power amplifier toward the right cowl side inner panel. d. Lower the power amplifier until the upper hook bracket is engaged in the upper hinge access hole in the right cowl side inner panel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Install and tighten the two screws that secure the power amplifier to the right cowl side inner panel. 4. Reconnect the two instrument panel wire harness connectors to the connector receptacles on the bottom of the power amplifier. 5. Install the trim cover onto the right cowl side inner panel. Refer to Cowl Trim Cover/Service and Repair of Body for the procedures. 6. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > CD Player - CD Compatibility Compact Disc Player (CD): Technical Service Bulletins CD Player - CD Compatibility BULLETIN NUMBER: 08-11-00 GROUP: Electrical DATE: March 24, 2000 SUBJECT: Recordable Compact Discs Used in Automotive CD players MODELS: 1989 - 2000 (AB) Ram Van/Wagon 1989 - 2000 (AN) Dakota 1994 - 2000 (BR/BE) Ram Truck 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GT 1997 - 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1997 - 2000 (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee DISCUSSION: Some recordable compact disc media, such as CD-R and CD-RW, may not comply with the standard CD format used in automotive CD players. When these CD's are used, customers may encounter error messages, skipping, or delaminating of the labels, which can cause an eject failure. It is important to question whether these kinds of CD media are being used. When customers encounter these symptoms, check the system with a known playable CD. Explain that the media may not be compatible with some automotive CD players. Replacing or exchanging the CD player will not address these issues. POLICY: Information Only Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations Remote Radio Switches Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 5678 Remote Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 5679 Remote Switch: Description and Operation DESCRIPTION A remote radio switch option is available on models equipped with the AM/FM/C D/cassette/3-band graphic equalizer (RAZ sales code) radio receiver and the high-line Central Timer Module (CTM). Refer to Central Timer Module in the Description and Operation of Instrument Panel Systems for more information on this component. 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 side is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right side is the volume control switch and has volume up, and volume down functions. 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 in the Description and Operation of Airbags and Seat Belts/Airbags for more information on this component. OPERATION 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 Chrysler Collision Detection (CCD) 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 CCD 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 5680 Remote Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. 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 Chrysler Collision Detection (CCD) data bus. If not OK, repair the open radio control mux circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 5681 Remote Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag module from the steering wheel. Refer to Driver Side Airbag Module Replacement of Air Bags and Seat Belts/Air Bags for the procedures. 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 Switches/Service and Repair of Speed Control System for the procedures. 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 Switches/Service and Repair of Speed Control System for the procedures. 5. Install the driver side airbag module onto the steering wheel. Refer to Driver Side Airbag Module Replacement of Air Bags and Seat Belts/Air Bags for the procedures. 6. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Specifications Speaker: Specifications Tighten the two screws that secure the front door upper speaker to the trim panel to 2 Nm (17 in. lbs.). Tighten the three screws that secure the speaker to the front door inner panel to 2 Nm (17 in. lbs.). Tighten the three screws that secure the speaker to the rear door inner panel to 2 Nm (17 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Specifications > Page 5685 Front Door Lower Speaker Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Specifications > Page 5686 Speaker: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Specifications > Page 5687 Speaker: Description and Operation DESCRIPTION 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. Premium The optional premium speaker system features eight Infinity model speakers in six 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 coaxial unit. The premium speaker system also includes an additional Infinity power amplifier. The total available power of the premium speaker system is about 100 watts. OPERATION Standard 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 eight Infinity speakers used in the premium speaker system are all driven by the radio receiver through an Infinity power amplifier. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Specifications > Page 5688 Speaker: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG 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 12 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 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 12 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Specifications > Page 5689 Speaker: Service and Repair REMOVAL Front Door Upper Speaker 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the front door. Front Door Upper Speaker Remove/Install 3. Disconnect the door wire harness connector from the front door upper speaker wire harness connector. 4. Remove the two screws that secure the front door upper speaker to the back of the trim panel. 5. Remove the front door upper speaker from the trim panel. Front Door Lower Speaker 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the front door. Front Door Lower Speaker Remove/Install 3. Remove the three screws that secure the speaker to the front door inner panel. 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 connector receptacle. 6. Remove the speaker from the front door inner panel. Rear Door Speaker 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the rear door. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Specifications > Page 5690 Rear Door Speaker Remove/Install 3. Remove the three screws that secure the speaker to the rear door inner panel. 4. Pull the speaker away from the mounting hole in the rear door inner panel far enough to access the wire harness connector. 5. Disconnect the rear door wire harness connector from the speaker connector receptacle. 6. Remove the speaker from the rear door inner panel. INSTALLATION Front Door Upper Speaker 1. Position the front door upper speaker to the back of the trim panel. 2. Install and tighten the two screws that secure the front door upper speaker to the trim panel. Tighten the screws to 2 Nm (17 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. Reconnect the battery negative cable. Front Door Lower Speaker 1. Position the speaker to the front door inner panel. 2. Reconnect the front door wire harness connector to the speaker connector receptacle. 3. Position the speaker into the mounting hole in the front door inner panel. 4. Install and tighten the three screws that secure the speaker to the front door inner panel. Tighten the screws to 2 Nm (17 in. lbs.). 5. Install the trim panel onto the front door. 6. Reconnect the battery negative cable. Rear Door Speaker 1. Position the speaker to the rear door inner panel. 2. Reconnect the rear door wire harness connector to the speaker connector receptacle. 3. Position the speaker into the mounting hole in the rear door inner panel. 4. Install and tighten the three screws that secure the speaker to the rear door inner panel. Tighten the screws to 2 Nm (17 in. lbs.). 5. Install the trim panel onto the rear door. 6. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams Arm/Disarm Switch: Diagrams Driver Door Arm/Disarm Switch Driver Door Arm/Disarm Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Description and Operation Door Sensor/Switch (For Alarm): Description and Operation SYSTEM 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Description and Operation > Page 5698 Door Sensor/Switch (For Alarm): Service and Repair REMOVAL AND INSTALLATION The door ajar switch is integral to the door latch unit. If the door ajar switch is faulty or damaged, the entire door latch unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Lock Cylinder Switch: Locations Door Lock Cylinder Switch Remove/Install - Typical Liftgate Lock Cylinder Switch Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 5702 Lock Cylinder Switch: Description and Operation SYSTEM DESCRIPTION Door Lock Cylinder Switch The door lock cylinder switches are mounted to the back of the key lock cylinder inside each front door. They are normally-open momentary switches that close to ground only when the lock cylinder is rotated to the unlock position. The door lock cylinder switches cannot be repaired and, if faulty or damaged, they must be replaced. Liftgate Lock Cylinder Switch The liftgate lock cylinder switch is mounted to the back of the key lock cylinder inside the liftgate. It is a normally-open momentary switch that closes to ground only when the lock cylinder is rotated to the unlock position. The liftgate lock cylinder switch cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 5703 Lock Cylinder Switch: Service and Repair REMOVAL AND INSTALLATION Door Lock Cylinder Switch 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 far enough to access the door lock cylinder switch. 4. Disengage the door lock cylinder switch from the back of the lock cylinder. 5. Unplug the door lock cylinder switch wire harness connector. 6. Disengage the retainers that secure the door lock cylinder switch wire harness to the inner door panel. 7. Remove the door lock cylinder switch from the door. 8. Reverse the removal procedures to install. Liftgate Lock Cylinder Switch 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 disengage the switch from the back of the liftgate lock cylinder. 4. Unplug the liftgate lock cylinder switch wire harness connector. 5. Remove the liftgate lock cylinder switch from the liftgate. 6. Reverse the removal procedures to install. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations Remote Radio Switches Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 5707 Remote Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 5708 Remote Switch: Description and Operation DESCRIPTION A remote radio switch option is available on models equipped with the AM/FM/C D/cassette/3-band graphic equalizer (RAZ sales code) radio receiver and the high-line Central Timer Module (CTM). Refer to Central Timer Module in the Description and Operation of Instrument Panel Systems for more information on this component. 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 side is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right side is the volume control switch and has volume up, and volume down functions. 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 in the Description and Operation of Airbags and Seat Belts/Airbags for more information on this component. OPERATION 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 Chrysler Collision Detection (CCD) 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 CCD 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 5709 Remote Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. 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 Chrysler Collision Detection (CCD) data bus. If not OK, repair the open radio control mux circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 5710 Remote Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag module from the steering wheel. Refer to Driver Side Airbag Module Replacement of Air Bags and Seat Belts/Air Bags for the procedures. 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 Switches/Service and Repair of Speed Control System for the procedures. 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 Switches/Service and Repair of Speed Control System for the procedures. 5. Install the driver side airbag module onto the steering wheel. Refer to Driver Side Airbag Module Replacement of Air Bags and Seat Belts/Air Bags for the procedures. 6. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Description and Operation Trunk/Liftgate Sensor/Switch (For Alarm): Description and Operation SYSTEM DESCRIPTION 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Description and Operation > Page 5714 Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair The liftgate ajar switch is integral to the liftgate latch unit. If the liftgate ajar switch is faulty or damaged, the entire liftgate latch unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5720 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5721 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5722 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5723 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5724 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5725 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5726 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5727 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5728 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5729 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5730 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5731 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5732 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5733 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5734 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5735 Trailer Connector: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5736 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5737 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 5744 Trailer Lighting Relay: Diagrams Power Distribution Center Trailer Tow Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5749 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5750 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5751 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5752 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5753 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5754 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5755 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5756 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5757 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5758 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5759 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5760 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5761 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5762 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5763 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5764 Trailer Connector: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5765 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5766 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Specifications Trip Computer: Specifications C/MTC Module to Overhead Console Housing Mounting Screws 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions Trip Computer: Diagram Information and Instructions Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5772 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5773 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5774 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5775 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5776 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5777 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5778 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5779 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5780 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5781 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5782 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5783 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5784 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5785 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5786 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5787 Trip Computer: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5788 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5789 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5790 Compass/Mini Trip Computer Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5791 Compass/Mini-Trip Computer Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Description and Operation > General Description Trip Computer: Description and Operation General Description DESCRIPTION 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 Chrysler Collision Detection (CCD) data bus network. The CCD 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 traveled 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 compass mini-trip computer module. Data input for all other compass mini-trip computer functions, including VFD dimming level, is received through CCD 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 CCD data bus. 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 may be required to restore proper compass operation. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Description and Operation > General Description > Page 5794 Trip Computer: Description and Operation Functional Description 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/100Km since the last reset. Instantaneous Fuel Economy Shows the fuel economy for the last few seconds in MPG or L/100Km. 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 minitrip 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, Trip Odometer, ET) is currently being displayed. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Description and Operation > Page 5795 Trip Computer: 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 Chrysler Collision Detection (CCD) 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. 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 CCD data bus. If not OK, repair the open fused ignition switch output (run/start) circuit to the junction block fuse as required. Self-Diagnostic Test 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. 2. Turn the ignition switch to the On position. 3. 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: a. Microprocessor compass circuit test b. Non-volatile memory read/write test c. Microprocessor ROM verification test d. CCD communications test. 4. Following completion of these tests, the compass mini-trip computer will return to normal operation or display one of two messages: "FAIL" or "CCD." Respond to these test results as follows: e. 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. f. If the "FAIL" message is displayed, the compass mini-trip computer module is faulty and must be replaced. g. If the "CCD" message is displayed, the use of a DRB scan tool and the proper Diagnostic Procedures are required for further diagnosis. h. 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. 5. If all tests are passed, or if the ignition switch is turned to the Off position, the compass mini-trip computer module will automatically return to normal operation. NOTE: 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Description and Operation > Page 5796 Trip Computer: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console from the headliner. Refer to Overhead Console/Service and Repair 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. 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/Service and Repair 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Locations Central Timer Module: Locations Module Locations CENTRAL TIMER MODULE The Durango utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The Base CTM does not communicate on the CCD bus and will not be addressed. The CTM performs most of the typical functions a Body Control Module would perform. The module is located on the right side of the glove box behind a metal bracket. It contains a white 18-way and a green 14-way connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN WHILE IN MOTION. DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 5804 Central Timer Module: 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Central Timer Module Central Timer Module: Description and Operation Central Timer Module DESCRIPTION Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the highline models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD 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. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. For diagnosis of the base version of the CTM, refer to Central Timer Module in the Diagnosis and Testing - Chime/Buzzer Warning Systems. For diagnosis of the high-line version of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-afterwash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermittent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. Refer to Central Timer module/Service and Repair of Instrument Panel Systems for the service procedures. See Wiper System Diagnosis and Testing for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. 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 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 Chrysler Collision Detection (CCD) 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. Refer to Remote Radio Switch in the Description and Operation for more information on this component. In addition, radio receivers connected to the CCD 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. The high-line CTM controls features and functions of the power lock, illuminated entry, and Remote Keyless Entry (RKE) systems. The high-line CTM receives hard wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio frequency inputs from the RKE transmitters. In response to those and many other inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the headlamp and horn relays, and the courtesy lamps. Some of the features and functions of the power lock, illuminated entry and RKE systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch when the driver door is open if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually, with a key, or energized with the RKE transmitter. - A programmable driver door unlock feature. The driver door unlock feature allows one press of the RKE transmitter Unlock button to unlock Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Central Timer Module > Page 5807 just the driver door, and a second press within five seconds to unlock all doors and the liftgate. If disabled, one press of the RKE transmitter Unlock button willunlock all doors and the liftgate. - A panic mode feature which can provide additional personal security and protection. When the Panic button on the RKE transmitter is depressed the vehicle horn will pulse, the headlights will flash, and the interior lights will illuminate on the vehicle for about three minutes, or until the Panic button is depressed a second time. A vehicle speed of about 24 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. - An enhanced accident response feature will unlock all doors and the liftgate, then prevent thepower door lock system from locking the doors and liftgate for a predetermined time interval, after receiving a CCD message from the ACM indicating a frontal impact of the vehicle requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates that the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors and the liftgate after the vehicle reaches a speed of about 24 kilometers-per-hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again, at any speed above 24 kilometers-per-hour (15 miles-per-hour). - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following activation of the RKE Lock function. This feature can be enabled or disabled and, if enabled, the horn chirp duration (twenty or forty milliseconds) can be selected. - Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the service procedures. - The programmable features of the CTM can be enabled or disabled using the DRB scan tool as described in the proper Diagnostic Procedures. These features can also be enabled/disabled using the customer programmable feature. See the owner's manual in the vehicle glove box for more information on the customer programmable feature. Refer to Central Timer Module in the Diagnosis and Testing for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. - One of the features that the high-line CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard- wired inputs from the door and liftgate ajar, door and liftgate lock cylinder, and ignition switches. The programming in the CTM allows it to process the information from these inputs and send control outputs to energize or de-energize the headlamp (or security) relay, horn relay, and the security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS - The high-line CTM also contains the receiver and control logic for the power lock and Remote Keyless Entry (RKE) systems, which are integrated into the arming, disarming, and triggering functions of the VTSS. - Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the service procedures. - For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. - One of the functions and features that both versions of the CTM support is the chime warning system. The CTM contains a chime tone generator to perform the functions of the chime warning module. The CTM uses hard-wired switch inputs, internal programming, and a hard-wired chime request input from the instrument cluster circuitry to detect when a chime tone is required. This covers the diagnosis and service of only the hard-wired inputs used by the CTM to determine that a chime tone should be generated. See Central Timer Module Diagnosis and Testing for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. OPERATION Some of the functions and features that the CTM supports or controls include: Chimes for the following conditions: - Headlamps on with ignition off and driver door open warning - Key in ignition with ignition off and driver door open warning - ABS lamp warning (if the vehicle is so equipped) - Airbag lamp warning - Check gauges lamp warning - Door ajar lamp warning - Low fuel lamp warning - Low washer fluid lamp warning - Seat belt reminder lamp warning Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Central Timer Module > Page 5808 - Transmission oil temperature lamp warning (automatic transmission) - Courtesy lamp defeat - Courtesy lamp time-out (high-line only) - Intermittent wipe control - Enhanced accident response (high-line only) - Horn chirp upon door lock with RKE (customer programmable) (high-line only) - Illuminated entry (high-line only) - Power door lock control (high-line only) - Power lock inhibit (high-line only) - Remote Keyless Entry (RKE) (high-line only) - Remote radio switches (high-line only) - Rolling door locks (customer programmable) (high-line only) - Speed sensitive intermittent wipe (high-line only) - Vehicle Theft Security System (VTSS) (high-line only) (if the vehicle is so equipped) - Wipe after wash (high-line only). More information on the operation of these CTM features and functions can be found in the system to which that feature or function applies. CENTRAL TIMER MODULE The Durango utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The Base CTM does not communicate on the CCD bus and will not be addressed. The CTM performs most of the typical functions a Body Control Module would perform. The Highline CTM provides the following features: Remote Keyless Entry (RKE) - Chime - Courtesy Lamp controls/Illuminated Entry - Power Door Locks - Speed Sensitive Intermittent Wipers - Enhanced Accident Response - Vehicle Theft Security System (VTSS) The module is located on the right side of the glove box behind a metal bracket. It contains a white 18-way and a green 14-way connector. Central Timer Module Diagnostic Trouble Codes - Door Disarm Switch Failure - Door Lock Switch Failure - Door Unlock Switch Failure - Wiper Park Switch Failure - EEPROM Checksum Failure - Internal ROM Test Failure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Central Timer Module > Page 5809 Central Timer Module: Description and Operation DRB III Error Messages and Blank Screen DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB will display one of only two error messages: User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, recored the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key itf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III Does Not Power Up (blank Screen) 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. Perform the "DRB Blank Screen" test under Vehicle Communication. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Information Bus/DRB Blank Screen DRB III Display Is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Central Timer Module > Page 5810 Central Timer Module: Description and Operation General Information Module Locations SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 1999 Durango consists of five modules that communicate over the CCD bus (Chrysler Collision Detection multiplex system). There are two additional modules, the Powertrain Control Module (PCM) and the Controller Anti-Lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication, The CAB also utilizes the bus for diagnostics. The PCM sends and receives messages on the CCD bus, however diagnostics are performed through the Serial Communication Interface (SCI), the same as previous years. All of the information about the functioning of all the systems is organized, controlled, and communicated by the CCD bus, which is described in Vehicle Communication. Through the CCD 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 the information to perform it's 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. 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 CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Mechanical Instrument Cluster (MIC) from the ACM via the CCD 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. Perform the WARNING LAMP CIRCUIT OPEN procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: warning lamp does not illuminate - warning lamp stays illuminated 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Central Timer Module > Page 5811 AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. CENTRAL TIMER MODULE The Durango utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The Base CTM does not communicate on the CCD bus and will not be addressed. The CTM performs most of the typical functions a Body Control Module would perform. The Highline CTM provides the following features: Remote Keyless Entry (RKE) - Chime - Courtesy Lamp controls/Illuminated Entry - Power Door Locks - Speed Sensitive Intermittent Wipers - Enhanced Accident Response - Vehicle Theft Security System (VTSS) The module is located on the right side of the glove box behind a metal bracket. It contains a white 18-way and a green 14-way connector. Chime system The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for seat belt, gauge problems and tell-tale warnings. There are two chime rates, Low; 50 ± 12 chimes per minute for reminders and High; 180 ± 12 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 doors are open or the headlights 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 approximately 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 - Seat belt warning - Check engine lamp illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Anti-lock lamp illuminated (after prove-out if equipped) - Check gauges lamp illuminated - Low fuel warning lamp illuminated - Low washer fluid - Door ajar 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/100Km since the last reset. Instantaneous Fuel Economy Shows the fuel economy for the last few seconds in MPG or L/100Km. 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 minitrip computer displays. US/M Button Press this button to convert all vehicle displays from US to Metric to US. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Central Timer Module > Page 5812 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, Trip Odometer, ET) is currently being displayed. 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. Enhanced Accident Response (Highline CTM Only) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the CCD bus to the CTM module to unlock the doors. The interior lights will be turned ON when the vehicle speed message on the CCD 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. Interior Lighting The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The highline CTM also provides for illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door disarm switch input or the door jamb switch input, the interior courtesy lights will be turned ON. The illuminated entry function is canceled if the CTM senses an ignition "ON" condition or the "lock" command from a valid key fob. If a door is left open or turned ON by rotation of dimmer switch for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned ON by courtesy lamp switch, the CTM will not be able to turn them OFF. The Durango utilizes an interior light defeat switch as an integral part of the headlamp switch. Mechanical Instrument Cluster (MIC) The MIC is available in 4 different versions. Two of the versions are Canadian clusters. There is a highline and a low line cluster available. The difference is the addition of a tachometer in the highline. In order to accomplish this, the fuel level gauge is reduced in size and oil pressure gauge is relocated. The cluster positions its gauges with bus messages received from the PCM. The odometer is a Liquid Crystal Display (LCD). The cluster will provide bus bias and the PCM provides termination. The MIC has an internal diagnostic routing that can be accessed by pushing and holding the trip odometer while rotating the key to the ON position. The cluster will then place all the gauges at their calibration points and will light all the CCD driven tell-tales. It will also light all the segments of the LCD display for a visual verification check. The MIC can verify communications with the PCM, ID the module, or change the country code by using options 1, 3, or 9 on the DRB III under the MIC menu. If there are faults found during the diagnostic routine, the cluster will report them on the LCD odometer display. Power Door Locks The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is OFF, the door is open, and the key is in the ignition. Automatic or "rolling locks" are included as a DRB III, or customer 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 CCD bus) indicating acceleration, the CTM will cycle the lock actuators to lock the doors. RKE/VTSS If the vehicle is equipped with Remote Keyless Entry (RKE), programming of additional transmitters and horn chirp are customer programmable features, The highline CTM provides for RKE and the Vehicle Theft Security System (VTSS). The base CTM is not able to provide these functions. The presence of either of these options dictates that the vehicle is equipped with a highline CTM. The VTSS system monitors the door ajar switches, liftgate 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, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes. After 15 minutes 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Central Timer Module > Page 5813 DRB III. The system may be disarmed by either an unlock command from a valid RKE key fob or by using a key in the lift gate or either door. Both front door key cylinders and the lift gate 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. The RKE system is placed in the programming mode by the DRB, or by using the customer programming sequence. The system will store up to four key fob codes. Two fobs are supplied with the truck, additional fobs may be purchased through parts department. The additional fobs can be programmed with the DRB III, or by using the customer programming sequence. 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. Speed Sensitive Intermittent Wipers The DN truck equipped with a highine CTM will utilize speed sensitive intermittent wipers. Only a highine CTM Will be able to support this feature. A base CTM will provide for intermittent wipers without the speed sensitive feature. 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. Diagnostics The CTM is fully addressable with the DRB III and it is the recommended method for diagnosis. The CTM reports 6 Diagnostic Trouble Codes. All of the inputs to the CTM can be read with the DRB and the outputs can be actuated. VEHICLE COMMUNICATION The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, and is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measureable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network" located in the module that supplies bus bias or voltage. Along with the module that supplies bias, some modules provide termination. Bias is the voltage necessary to make the bus operational. At least one point of termination is necessary, some systems may use more than one. Some modules are capable of both biasing and terminating. Termination in the circuitry (a 120 ohm resistor placed across the bus) is required to complete the voltage divider network circuit and also provide some electromagnetic protection for the bus. In this vehicle, the bias is supplied by the instrument cluster and termination is provided by the PCM and the instrument cluster. Without termination, voltage on the bus goes to approximately 5 volts on one wire and 0 volts on the other wire. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB III. Problems with the operation of the bus or DRB III must corrected before proceeding with diagnostic testing. Bus Failure Messages Short to Battery - Either or both of the bus wires are shorted to the battery potential, or Open ground to any CCD bus module. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of the bus wires are shorted to ground. Bus (+) L Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with the Instrument Cluster. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Central Timer Module > Page 5814 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. The procedure begins with AIRBAG TEST 1A-Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. 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 for 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 occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. 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 the 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, the 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. Airbag Diagnostic Trouble Codes The airbag control module may report any of the following diagnostic trouble codes. For the following codes, replace the Airbag Control Module (ACM) even if set intermittently: ACM Accelerometer - Internal Diagnostic 1 - Internal Diagnostic 2 For the following codes, replace the Airbag Control Module (ACM): ACM Output Driver - ACM Stored Energy Logic - ACM Stored Energy Driver - ACM Stored Energy Passenger - Internal Diagnostic 3 - Internal Diagnostic 4 - Safing Sensor Shorted - Warning Lamp Driver Error For these codes, refer to the appropriate diagnostic procedure: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Central Timer Module > Page 5815 - Driver Squib Open - Driver Squib Shorted - Loss of Ignition Run Only - Loss of Ignition Run/Start - No CCD Communication - Passenger Squib Circuit Open - Passenger Squib Circuit Shorted - Either Squib Terminal Short to Battery - Either Squib Terminal Short to Ground - Warning Lamp Circuit Open - Warning Circuit Shorted Central Timer Module Diagnostic Trouble Codes - Door Disarm Switch Failure - Door Lock Switch Failure - Door Unlock Switch Failure - Wiper Park Switch Failure - EEPROM Checksum Failure - Internal ROM Test Failure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 AM/FM Switch Inoperative SYMPTOM AM-FM SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Balance Dial Inoperative SYMPTOM BALANCE DIAL INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative CD Eject Switch Inoperative SYMPTOM CD EJECT SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Equalizer Inoperative SYMPTOM EQUALIZER INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative External CD Changer (If Equipped) SYMPTOM * EXTERNAL CD CHANGER (IF EQUIPPED) POSSIBLE CAUSES - CD cable assembly defective - CD changer defective - Defective radio Fader Dial Inoperative SYMPTOM FADER DIAL INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative FF/RW Switch Inoperative SYMPTOM Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5818 FF/RW SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Hour/Minute Switch Inoperative SYMPTOM HOUR/MINUTE SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative No Sound From All Speakers SYMPTOM * NO SOUND FROM ALL SPEAKERS POSSIBLE CAUSES - Radio 12 V output circuit defective - Radio defective - Radio defective - Fused B(+) circuit open - Ground circuit open - Defective radio No Sound From One Speaker SYMPTOM * NO SOUND FROM ONE SPEAKER POSSIBLE CAUSES - Pillar speaker (+) circuit open - Pillar speaker (-) circuit open - Pillar speaker defective - Speaker (-) circuit shorted - Speaker defective - Amplifier speaker (+) circuit open - Amplifier speaker (-) circuit open - Power amplifier defective - Power amplifier defective Pause/Play Switch Inoperative SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Poor Sound Quality All Speakers SYMPTOM * POOR SOUND QUALITY ALL SPEAKERS POSSIBLE CAUSES - Antenna connector connection defective - Radio 12 V output circuit defective - Radio connections defective - Radio defective Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5819 - Radio defective - Fused B(+) circuit open - Ground circuit open - Radio choke relay connection defective Poor Sound Quality From One Speaker SYMPTOM * POOR SOUND QUALITY FROM ONE SPEAKER POSSIBLE CAUSES - Pillar/lower speaker (+) circuit open - Pillar lower speaker (-) circuit open - Pillar speaker defective - Radio defective - Radio defective - Speaker (+) circuit open - Speaker (-) circuit open - Speaker defective PWR Switch Inoperative SYMPTOM PWR SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Remote Steering Wheel Switches (If Equipped) SYMPTOM * REMOTE STEERING WHEEL SWITCHES (IF EQUIPPED) POSSIBLE CAUSES - MUX control clockspring defective - Radio control circuit defective open - Radio control switch ground circuit open - Radio MUX control circuit defective - Remote control switch defective - No response CCD bus failure - Radio control MUX circuit open - Central timer module defective Scan Switch Inoperative SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Seek Switch Inoperative SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5820 Set Switch Inoperative SYMPTOM SET SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Shorted Front Channel SYMPTOM SHORTED FRONT CHANNEL POSSIBLE CAUSES - Radio defective - Right front SPKR (+) circuit short to ground - Right front SPKR (-) circuit short to ground - Left front SPKR (+) circuit short to ground - Left front SPKR (-) circuit short to ground Shorted Left Channel SYMPTOM SHORTED LEFT CHANNEL POSSIBLE CAUSES - Left rear SPKR (+) circuit short to ground - Left rear SPKR (-) circuit short to ground - Left front SPKR (+) circuit short to ground - Left front SPKR (-) circuit short to ground - Radio defective Shorted Rear Channel SYMPTOM SHORTED REAR CHANNEL POSSIBLE CAUSES - Left rear SPKR (+) circuit short to ground - Left rear SPKR (-) circuit short to ground - Radio defective - Right rear SPKR (+) circuit short to ground - Right rear SPKR (-) circuit short to ground Shorted Right Channel SYMPTOM SHORTED RIGHT CHANNEL POSSIBLE CAUSES - Right rear SPKR (+) circuit short to ground - Right rear SPKR (-) circuit short to ground - Right front SPKR (+) circuit short to ground - Radio defective - Right front SPKR (-) circuit short to ground Tape Eject Switch Inoperative SYMPTOM TAPE EJECT SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5821 Tune Switch Inoperative SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Volume/Time Switch Inoperative SYMPTOM VOL/TIME SWITCH INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative 1-5 Presets Inoperative SYMPTOM 1-5 PRESETS INOPERATIVE POSSIBLE CAUSES - Radio function controls inoperative Chime Inoperative - Engine Temperature Critical SYMPTOM * CHIME INOPERATIVE - ENGINE TEMPERATURE CRITICAL POSSIBLE CAUSES - Tone request circuit open - Instrument cluster tone request output defective - CTM fails chime test - PCM DTC - coolant temp check Chime Inoperative - Key In Ignition & LF Door Open SYMPTOM * CHIME INOPERATIVE - KEY IN IGNITION & LF DOOR OPEN POSSIBLE CAUSES - Key in ignition SW sense CKT open - Ignition SW-key in SW open - CTM no chime to key in ignition - CTM not responding to key in SW Chime Inoperative at All Times SYMPTOM * CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM fails internal chime test Chime Inoperative With Exterior Lamps On SYMPTOM * CHIME INOPERATIVE WITH EXTERIOR LAMPS ON POSSIBLE CAUSES - Headlamp switch circuit open Chime Inoperative With Low Oil Pressure Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5822 SYMPTOM * CHIME INOPERATIVE WITH LOW OIL PRESSURE POSSIBLE CAUSES - Oil pressure sender ground circuit open - Tone request circuit open - Instrument cluster - oil press defective - CTM no response to oil pressure default - CTM fails chime test Chime Sounds With Driver Door Open SYMPTOM * CHIME SOUNDS WITH DRIVER DOOR OPEN POSSIBLE CAUSES - Key in ignition switch sense circuit short to ground - Ignition SW - key in SW shorted - CTM - key in sense short default - CTM not responding to key out Open Driver Door Ajar Circuit SYMPTOM * OPEN DRIVER DOOR AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Left front ajar switch sense circuit open - Left front door ajar switch defective shorted - Left front door ajar switch sense circuit open Open Gate Ajar Circuit SYMPTOM * OPEN GATE AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Liftgate ajar switch sense circuit defective open - Liftgate door ajar ground circuit defective open - Liftgate door ajar switch defective open Open Left Rear Door Ajar Circuit SYMPTOM * OPEN LEFT REAR DOOR AJAR CIRCUIT POSSIBLE CAUSES - Left rear door ajar switch sense circuit defective open - CTM defective - Ground circuit defective open - Left rear door ajar switch defective open Open Right Front Door Ajar Circuit SYMPTOM * OPEN RIGHT FRONT DOOR AJAR CIRCUIT POSSIBLE CAUSES - RF door ajar switch sense (ground circuit) open - Right front door ajar switch sense circuit open - CTM defective - Right front door ajar switch defective open Open Right Rear Door Ajar Circuit SYMPTOM * OPEN RIGHT REAR DOOR AJAR CIRCUIT Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5823 POSSIBLE CAUSES - Right rear door ajar switch sense circuit defective open - CTM defective - Ground circuit defective open - Right rear door ajar switch defective open Shorted Driver Door Ajar Circuit SYMPTOM * SHORTED DRIVER DOOR AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Left front door ajar switch defective shorted - LF door ajar switch sense circuit short to GND Shorted Gate Ajar Circuit SYMPTOM * SHORTED GATE AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Liftgate ajar switch defective shorted - Liftgate ajar switch sense circuit defective short to GND Shorted Passenger Door Ajar Circuit SYMPTOM * SHORTED PASSENGER DOOR AJAR CIRCUIT POSSIBLE CAUSES - CTM defective - Door ajar switch sense circuit short to ground - Right front door ajar switch defective shorted - Right rear door ajar switch DEF shorted - Left rear door ajar switch DEF shorted All Gauges Inoperative SYMPTOM * ALL GAUGES INOPERATIVE POSSIBLE CAUSES - No response/CCD bus (MIC) - Fuse #17 open - Fused ignition switch output circuit open - Instrument cluster defective Any CCD Cluster Warning Lamp Inoperative SYMPTOM * ANY CCD CLUSTER LAMP INOPERATIVE POSSIBLE CAUSES - No response/CCD bus (MIC) - CCD inoperative lamp/bulb defective - CCD lamp cluster input defective - Defective cluster - CCD LP cluster test complete Any Hard Wired Cluster Warning Lamp SYMPTOM * ANY HARD WIRED LAMP INOPERATIVE POSSIBLE CAUSES - Hard wired lamp circuit open Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5824 - Inoperative lamp/bulb defective - Defective instrument cluster One Gauge Not Operating Properly SYMPTOM * ONE GAUGE NOT OPERATING PROPERLY POSSIBLE CAUSES - Gauge not reading 4 PSI> engine warm at idle - Oil gauge not reading 4 PSI Or > at idle - Oil level low - Instrument cluster circuit board defective - Oil pressure sensor defective - Instrument cluster defective - Oil pressure sense circuit open - Oil pressure sense signal CKT short to ground - Cooling system operation faulty - DRB shows ECT sensor voltage too high - DRB shows ECT sensor voltage too low - Check for PCM DTC'S - Defective JTEC module - Fuel gauge inoperative - JTEC module defective - Oil pressure switch defective - Pinion factor incorrect - Powertrain control module defective - Tachometer inoperative - Voltage gauge inoperative Average MPH/Fuel Econ Inoperative or Wrong SYMPTOM * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG POSSIBLE CAUSES - Defective compass/mini-trip computer CMTC Display Shows Failed SYMPTOM * CMTC DISPLAY SHOWS FAILED POSSIBLE CAUSES - Defective CMTC display failed CMTC Fails to Respond to Instrument Panel Dimming SYMPTOM * CMTC FAILS TO RESPOND TO INSTRUMENT PANEL DIMMING TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer CMTC Segments Fail to Light Up SYMPTOM * CMTC SEGMENTS FAIL TO LIGHT UP POSSIBLE CAUSES - Defective compass mini-trip computer-segments fail to light Distance to Empty Inoperative or Wrong SYMPTOM * DISTANCE TO EMPTY INOPERATIVE OR WRONG Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5825 TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer Elapsed Time Inoperative/Wrong SYMPTOM * ELAPSED TIME INOPERATIVE/WRONG TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer Repairing OC In CMTC Display SYMPTOM * REPAIRING "OC" IN CMTC DISPLAY POSSIBLE CAUSES - Open sensor ground circuit - Defective ambient temperature sensor-SC - Open ambient temperature sensor signal circuit - Defective CMTM/OC default Repairing SC In CMTC Display SYMPTOM * REPAIRING "OC" IN CMTC DISPLAY POSSIBLE CAUSES - Ambient temperature sensor signal CKT-SH/sensor GND - Defective ambient temperature sensor-OC - Ambient temperature sensor signal CKT-short/GND - Defective CMTM/SC default Switch on Compass Mini-Trip Computer Inoperative SYMPTOM * SWITCH ON COMPASS MINI-TRIP COMPUTER INOPERATIVE TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer Trip Odometer Inoperative/Wrong SYMPTOM * TRIP ODOMETER INOPERATIVE/WRONG TEST NOTE: This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective compass/mini-trip computer Automatic (Rolling) Door Locks Inoperative SYMPTOM * AUTOMATIC (ROLLING) DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Link to body communication bus inoperative Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5826 - Speed sensing door locks inoperative Doors Lock With Key In Ignition and Left Door Open SYMPTOM * DOORS LOCK WITH KEY IN IGNITION AND LEFT DOOR OPEN POSSIBLE CAUSES - Link to body communication bus inoperative - Ignition switch shorted - Key-in ignition switch sense circuit open - CTM input A9 short to ground - CTM input shorted to ground One or All Doors Failing to Lock From One Switch SYMPTOM * ONE OR ALL DOORS FAILING TO LOCK FROM ONE SWITCH POSSIBLE CAUSES - Link to body communication bus inoperative - Door lock actuator assembly defective - Door unlock actuator assembly defective - Door lock switch assembly open - Door unlock switch assembly open - Door lock driver circuit open - Fused B (+) circuit open - Door lock driver circuit open - Power door lock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - CTM lock driver input open - CTM unlock driver input open - Lock driver circuit on CTM open - Unlock driver circuit on CTM open One or All Doors Failing to Unlock From One Switch SYMPTOM * ONE OR ALL DOORS FAILING TO UNLOCK FROM ONE SWITCH TEST NOTE: This symptom is diagnosed using the test * ONE OR ALL DOORS FAILING TO LOCK FROM ONE SWITCH. POSSIBLE CAUSES - Link to body communication bus inoperative - Door lock actuator assembly defective - Door unlock actuator assembly defective - Door lock switch assembly open - Door unlock switch assembly open - Door lock driver circuit open - Fused B (+) circuit open - Door lock driver circuit open - Power door lock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - CTM lock driver input open - CTM unlock driver input open - Lock driver circuit on CTM open - Unlock driver circuit on CTM open Remote Keyless Entry Problem SYMPTOM * REMOTE KEYLESS ENTRY PROBLEM POSSIBLE CAUSES - Link to body communication bus inoperative Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5827 - Transmitter defective - Circuit between CTM & left front UNLCK RLY open - Door unlock relay defective - Door unlock relay internal defect - Left front door unlock relay coil out of tolerance - Left front door unlock relay B (+) circuit open - Unlock relay B (+) circuit open (CAV 87) - CTM defective-RKE function - CTM unlock relay signal inoperative - Left front door unlock relay circuit at CTM open Intermittent Wipers Inoperative SYMPTOM * INTERMITTENT WIPERS INOPERATIVE POSSIBLE CAUSES - No response/CCD bus failure - CTM - Open intermittent wiper mode sense CKT - Open wiper park switch sense CKT - Defective wiper motor/12 volts - Defective CTM/12 volt default - Defective CTM/STALK switch - Defective multi-function switch/5.0 ohms No Wipe After Washers Actuated SYMPTOM * NO WIPE AFTER WASHERS ACTUATED POSSIBLE CAUSES - CCD bus failure-no response CTM - Open front washer switch sensor CKT - Defective CTM/washer pump Wiper Speed Sensitive Feature Inoperative SYMPTOM * WIPER SPEED SENSITIVE FEATURE INOPERATIVE POSSIBLE CAUSES - CCD bus failure-CTM - CCD bus failure PCM - Defective CTM/wiper intervals Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5828 Central Timer Module: Component Tests and General Diagnostics 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 SCREEN WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5829 Central Timer Module: Scan Tool Testing and Procedures Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, recored the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key itf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III Does Not Power Up (blank Screen) 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. Perform the "DRB Blank Screen" test under Vehicle Communication. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Information Bus/DRB Blank Screen DRB III Display Is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 5830 Central Timer Module: Tools and Equipment DRB III (Diagnostic Read Out Box) Jumper Wires Ohmmeter Voltmeter Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5857 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments > Page 5864 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments > Page 5865 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures Front Door Panel: Procedures Front Door Trim Panel REMOVAL 1. Release door latch and open door. 2. Roll window down. 3. Remove window crank if equipped. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures > Page 5870 5. Simultaneously lift upward and outward to release retainer steps from inner door panel. 6. Disengage inside handle linkage rod from inside handle. 7. Disconnect speaker harness wire connector. 8. Disengage power mirror wire connector, if equipped (driver's side only). 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures > Page 5871 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. FRONT DOOR WATERDAM REMOVAL 1. Remove the trim panel from the door. 2. Carefully separate the waterdam from the door inner panel at the areas with adhesive. Remove the waterdam from the door inner panel. INSTALLATION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures > Page 5872 Front Door Panel: Removal and Replacement Trim Panel TRIM PANEL REMOVAL 1. Roll window down. Fig. 10 2. Remove window crank (Fig. 10), if equipped. Fig. 11 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures > Page 5873 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures > Page 5874 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. Waterdam Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures > Page 5875 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Opening Front Door Weatherstrip: Service and Repair Front Door Opening REMOVAL 1. Remove A-pillar trim. 2. Remove lower cowl trim. 3. Remove door sill trim. 4. Loosen upper and lower B-pillar trim to access weatherstrip. 5. Pull weatherstrip from pinch flange around door opening. 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. Ensure the clips attaching the sill trim to the door sill are fully seated. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Opening > Page 5883 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Opening > Page 5884 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Opening > Page 5885 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Opening > Page 5886 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Glass Run Weatherstrip 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Glass Run Weatherstrip > Page 5892 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Glass Run Weatherstrip > Page 5893 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Glass Run Weatherstrip > Page 5894 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 5898 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5904 5. Install waterdam. 6. Install trim panel. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Trim Panel 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Trim Panel > Page 5915 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Trim Panel > Page 5916 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5924 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5925 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5926 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5927 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5933 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5934 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 5935 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 5939 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Latch > Page 5955 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair > Page 5959 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Striker > Component Information > Description and Operation > Page 5966 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Hood Seal > Page 5971 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Molding 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Molding > Page 5983 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Transfer Case Skid Plate Skid Plate: Service and Repair Transfer Case Skid Plate TRANSFER CASE SKID PLATE REMOVAL 1. Remove the front skid plate. Fig. 10 2. Remove the rear bolts and remove the skid plate. (Fig. 10) INSTALLATION 1. Position skid plate on vehicle. 2. Install two rear bolts and tighten to 23 N.m (17 ft.lbs.). 3. Install the front axle skid plate. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Transfer Case Skid Plate > Page 6023 Skid Plate: Service and Repair Front Axle Skid Plate FRONT AXLE SKID PLATE REMOVAL 1. Raise and support the vehicle. 2. Support the skid plate with a suitable lifting device. Fig. 6 3. Remove the bolts that attach the skid plate to the front crossmember. (Fig. 6) 4. Remove the bolts that attach the skid plate to the skid plate crossmember. 5. Separate the crossmember from the vehicle. INSTALLATION 1. Position and support the skid plate at the front crossmember. 2. Install the bolts that attach the skid plate to the transmission crossmember and tighten to 23 N.m (17 ft.lbs.). 3. Install the bolts that attach the skid plate to the front crossmember and tighten to 23 N.m (17 ft.lbs.). 4. Remove the support from under the skid plate. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Transfer Case Skid Plate > Page 6024 Skid Plate: Service and Repair Fuel Tank Skid Plate 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6040 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch Technical Service Bulletin # 23-32-99 Date: 990827 Center Console/Armrest Lid - Hard To Latch NUMBER: 23-32-99 GROUP: Body EFFECTIVE DATE: Aug. 27, 1999 SUBJECT: Center Console/Armrest Lid Hinge Is Bent OVERVIEW: This bulletin involves replacing the center console/armrest lid. MODELS: 1998 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 40/20/40 SPLIT BENCH FRONT SEAT (EQUIPPED WITH THE FRONT CENTER CONSOLE/ARMREST) BUILT AFTER OCTOBER 13, 1997 (MDH 1O13XX). SYMPTOM/CONDITION: The center console/armrest lid difficult to latch due to a bent lid hinge. DIAGNOSIS: 1. Place the center console/armrest in the down position. 2. Open and close the center console/armrest lid. Proceed to the next step if the center console/armrest lid does not latch when closed. 3. Check the alignment of the lid with the console by looking for witness marks on the latch cover bezel (Figure 1) that may have been caused by the striker coming in contact with the bezel. If there are witness marks on the latch cover bezel, perform the Repair Procedure. If there are no witness marks on the latch cover bezel but the lid does not latch properly, perform Technical Service Bulletin 23-12-99, dated April 23, 1999. PARTS REQUIRED: AR (1) 05016751AA Lid, Center Console/Armrest, Agate AR (1) 05016754AA Lid, Center Console/Armrest, Mist Gray AR (1) 05016755AA Lid, Center Console/Armrest, Camel 1 04883611AA Bezel, Latch Cover POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6045 Labor Operation No: 23-14-15-94 0.2 Hrs. FAILURE CODE: 8 - New Part 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. Place the center console/armrest in the down position. 2. Open the center console/armrest lid to the full open position. 3. Remove the two hinge cover attachment screws from the hinge lid (Figure 2). 4. Close the armrest lid and remove the hinge cover. 5. Move the seats to the full forward position. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6046 6. Using a hammer, carefully tap the hinge pin until the pin is flush with the hinge (Figure 3). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6047 7. Once the hinge pin is flush, open the lid, then insert the steel rod (supplied in the kit) into the hinge and continue tapping (Figure 4.) until the hinge pin is flush with the console portion of the hinge and the lid pops to one side (Figure 5). WARNING: THE LONG LEG OF THE CENTER CONSOLE/ARMREST LID SPRING WILL POP OUT OF THE LID WHILE THE HINGE PIN IS BEING REMOVED. TAKE CARE TO KEEP CLEAR OF THE SPRING LEG WHEN REMOVING THE HINGE PIN FROM THE LID. 8. With the lid to the side, continue driving the hinge pin from the center console/armrest assembly until the hinge pin is free from the assembly (Figure 6). NOTE: THE SUPPLIED STEEL ROD IS DESIGNED TO PROPERLY RETAIN THE HINGE LID SPRING DURING ASSEMBLY. DO NOT REMOVE THE STEEL ROD UNTIL THE NEW LID IS IN PLACE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6048 9. Remove the lid. 10. Engage the long leg of the center console/armrest lid spring into the hole of the new lid) see Parts Required section) (Figure 7). 11. Start the hinge pin into the new lid. With the lid in the upright position, align the lid hinges with the hinges of the lower portion of the console /armrest. Then, slide the hinge pin through the hinge (Figure 8). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6049 12. Close the lid (Figure 9) then, finish installing the hinge pin by tapping it lightly with a hammer until the hinge pin has secured the lid to the console . 13. Continue installing the hinge pin until the pin is positioned as shown in Figure 10. 14. Attach the hinge cover. 15. Open the center console/armrest lid and install the two screws that secure the hinge cover to the center console/armrest lid (Figure 2). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6050 16. Remove the two screws attaching the latch cover bezel (Figure 11), and then remove the latch cover bezel. 17. Install a new latch cover bezel onto the center console. Secure the bezel with the two screws. 18. Close the lid. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-12-99 > Apr > 99 > Center Console/Armrest Cover - Will Not Latch Technical Service Bulletin # 23-12-99 Date: 990423 Center Console/Armrest Cover - Will Not Latch NUMBER: 23-12-99 GROUP: Body DATE: April 23, 1999 SUBJECT: Center Console/Armrest Cover Will Not Latch OVERVIEW: This bulletin involves removing and installing a new center console/armrest latch assembly. MODELS: 1998 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 40/20/40 SPLIT BENCH FRONT SEAT (EQUIPPED WITH THE FRONT CENTER CONSOLE/ARMREST) BUILT AFTER OCTOBER 13, 1997 (MDH 1O13XX). SYMPTOM/CONDITION: Center console/armrest will not latch. DIAGNOSIS: 1. Place the center console/armrest in the down position. 2. Open and close the center console/armrest. Proceed to the next step it the center console/armrest does not latch when closed. 3. Open the center console/armrest lid and remove the two screws attaching the latch bezel cover (Figure 1), then remove the latch cover bezel and latch button. 4. Check the alignment of the lid latch striker with the latch for proper alignment. If the striker and latch do not mate properly, the lid hinge is probably sprung and will require replacement. If the latch and striker line up properly, perform the Repair Procedure. PARTS REQUIRED: 1 05015638AA Center Console/Armrest Latch Repair Kit Includes: (1) Latch Assembly (2) Rivets (1) Latch Button (1) Latch Bezel EQUIPMENT REQUIRED: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-12-99 > Apr > 99 > Center Console/Armrest Cover - Will Not Latch > Page 6055 3/8 in. Drill Bit 7/32 in. Drill Bit 11/64 in. Drill Bit Rivet Gun POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-41-36-90 0.3 Hrs. FAILURE CODE: P8 - New Part 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. With the center console/armrest down, lid open, and the bezel removed, drill the head of the two latch rivets with a 3/8 in. drill bit until the head of the rivet detaches from the rivet. NOTE: DO NOT DRILL INTO THE LATCH BRACKET. ONLY DRILL THE HEAD OF THE RIVET OFF. 2. Remove the latch assembly. 3. Using the 7/32 in. drill bit, drill the rivet until the rivet is flush with the steel frame. 4. Using the 11/64 in. drill bit, drill the remaining portion of the rivet until the rivet is just behind the steel bin frame. 5. Using an awl or similar object, maneuver the remaining portion of the rivet rearward and to the side behind the steel bin frame until the rivet is out of visible sight. NOTE: IN ORDER TO FREE THE RIVET FROM THE STEEL FRAME, IT MAY BE NECESSARY TO DRIVE THE RIVET TO THE SIDE USING A MALLET AND A PUNCH/AWL. TO PREVENT STRESS MARKS FROM OCCURRING ON THE INTERIOR OF THE CENTER CONSOLE/ARMREST BIN WALL, DO NOT PUSH OR HIT THE RIVET TOO HARD. 6. Clean all metal filings from the center console/armrest latch area. 7. Align the holes of the new latch assembly from kit p/n 05015638AA with the holes located on the steel bin frame. 8. Using a rivet gun and the two rivets supplied in the kit, secure the latch assembly. 9. Place the new latch button into position, then install the new latch cover bezel. Secure the latch cover bezel with the two screws. 10. Verify latch operation by latching and unlatching the lid and cycling the lid through the full range of lid motion. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-02-99 > Jan > 99 > Center Armrest - Lid Rattles Arm Rest: Customer Interest Center Armrest - Lid Rattles NUMBER: 23-02-99 GROUP: Body DATE: Jan. 29, 1999 SUBJECT: Center Armrest Lid Rattles OVERVIEW: This bulletin involves installing a stop bumper on the center armrest's striker bezel. MODELS: 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 40-20-40 FRONT SEAT (SALES CODE CBE) BUILT BETWEEN MARCH 23, 1998 (MDH 0328XX) AND OCTOBER 17, 1998 (MDH 1016XX). SYMPTOM/CONDITION: Center armrest lid rattles. DIAGNOSIS: With the center armrest in the down position and the lid latched, tap on the lid directly above the striker and listen for the lid to rattle. If the lid rattles, perform the Repair Procedure. PARTS REQUIRED: 1 05015588AA Stop Bumper Kit Consisting Of: 1 Screw 1 Bumper 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. Open the center armrest cover. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-02-99 > Jan > 99 > Center Armrest - Lid Rattles > Page 6060 2. Remove the driver side screw that attaches the striker bezel to the underside of the armrest cover (Figure 1). 3. Insert the new screw from bumper kit p/n 05015588AA into the new stop bumper. Then. install the stop bumper screw assembly into the location where the screw was removed in Step 2. 4. Verify that the center armrest cover closes easily and that the rattle is gone. If the center armrest cover is difficult to close, the armrest cover can be carefully bent up at the ends (in the direction of a smile) to adjust the tension between the stop bumper and the cover. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-14-21-91 0.2 Hrs. FAILURE CODE: PS - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6066 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch Technical Service Bulletin # 23-32-99 Date: 990827 Center Console/Armrest Lid - Hard To Latch NUMBER: 23-32-99 GROUP: Body EFFECTIVE DATE: Aug. 27, 1999 SUBJECT: Center Console/Armrest Lid Hinge Is Bent OVERVIEW: This bulletin involves replacing the center console/armrest lid. MODELS: 1998 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 40/20/40 SPLIT BENCH FRONT SEAT (EQUIPPED WITH THE FRONT CENTER CONSOLE/ARMREST) BUILT AFTER OCTOBER 13, 1997 (MDH 1O13XX). SYMPTOM/CONDITION: The center console/armrest lid difficult to latch due to a bent lid hinge. DIAGNOSIS: 1. Place the center console/armrest in the down position. 2. Open and close the center console/armrest lid. Proceed to the next step if the center console/armrest lid does not latch when closed. 3. Check the alignment of the lid with the console by looking for witness marks on the latch cover bezel (Figure 1) that may have been caused by the striker coming in contact with the bezel. If there are witness marks on the latch cover bezel, perform the Repair Procedure. If there are no witness marks on the latch cover bezel but the lid does not latch properly, perform Technical Service Bulletin 23-12-99, dated April 23, 1999. PARTS REQUIRED: AR (1) 05016751AA Lid, Center Console/Armrest, Agate AR (1) 05016754AA Lid, Center Console/Armrest, Mist Gray AR (1) 05016755AA Lid, Center Console/Armrest, Camel 1 04883611AA Bezel, Latch Cover POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6071 Labor Operation No: 23-14-15-94 0.2 Hrs. FAILURE CODE: 8 - New Part 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. Place the center console/armrest in the down position. 2. Open the center console/armrest lid to the full open position. 3. Remove the two hinge cover attachment screws from the hinge lid (Figure 2). 4. Close the armrest lid and remove the hinge cover. 5. Move the seats to the full forward position. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6072 6. Using a hammer, carefully tap the hinge pin until the pin is flush with the hinge (Figure 3). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6073 7. Once the hinge pin is flush, open the lid, then insert the steel rod (supplied in the kit) into the hinge and continue tapping (Figure 4.) until the hinge pin is flush with the console portion of the hinge and the lid pops to one side (Figure 5). WARNING: THE LONG LEG OF THE CENTER CONSOLE/ARMREST LID SPRING WILL POP OUT OF THE LID WHILE THE HINGE PIN IS BEING REMOVED. TAKE CARE TO KEEP CLEAR OF THE SPRING LEG WHEN REMOVING THE HINGE PIN FROM THE LID. 8. With the lid to the side, continue driving the hinge pin from the center console/armrest assembly until the hinge pin is free from the assembly (Figure 6). NOTE: THE SUPPLIED STEEL ROD IS DESIGNED TO PROPERLY RETAIN THE HINGE LID SPRING DURING ASSEMBLY. DO NOT REMOVE THE STEEL ROD UNTIL THE NEW LID IS IN PLACE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6074 9. Remove the lid. 10. Engage the long leg of the center console/armrest lid spring into the hole of the new lid) see Parts Required section) (Figure 7). 11. Start the hinge pin into the new lid. With the lid in the upright position, align the lid hinges with the hinges of the lower portion of the console /armrest. Then, slide the hinge pin through the hinge (Figure 8). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6075 12. Close the lid (Figure 9) then, finish installing the hinge pin by tapping it lightly with a hammer until the hinge pin has secured the lid to the console . 13. Continue installing the hinge pin until the pin is positioned as shown in Figure 10. 14. Attach the hinge cover. 15. Open the center console/armrest lid and install the two screws that secure the hinge cover to the center console/armrest lid (Figure 2). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6076 16. Remove the two screws attaching the latch cover bezel (Figure 11), and then remove the latch cover bezel. 17. Install a new latch cover bezel onto the center console. Secure the bezel with the two screws. 18. Close the lid. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-12-99 > Apr > 99 > Center Console/Armrest Cover Will Not Latch Technical Service Bulletin # 23-12-99 Date: 990423 Center Console/Armrest Cover - Will Not Latch NUMBER: 23-12-99 GROUP: Body DATE: April 23, 1999 SUBJECT: Center Console/Armrest Cover Will Not Latch OVERVIEW: This bulletin involves removing and installing a new center console/armrest latch assembly. MODELS: 1998 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 40/20/40 SPLIT BENCH FRONT SEAT (EQUIPPED WITH THE FRONT CENTER CONSOLE/ARMREST) BUILT AFTER OCTOBER 13, 1997 (MDH 1O13XX). SYMPTOM/CONDITION: Center console/armrest will not latch. DIAGNOSIS: 1. Place the center console/armrest in the down position. 2. Open and close the center console/armrest. Proceed to the next step it the center console/armrest does not latch when closed. 3. Open the center console/armrest lid and remove the two screws attaching the latch bezel cover (Figure 1), then remove the latch cover bezel and latch button. 4. Check the alignment of the lid latch striker with the latch for proper alignment. If the striker and latch do not mate properly, the lid hinge is probably sprung and will require replacement. If the latch and striker line up properly, perform the Repair Procedure. PARTS REQUIRED: 1 05015638AA Center Console/Armrest Latch Repair Kit Includes: (1) Latch Assembly (2) Rivets (1) Latch Button (1) Latch Bezel EQUIPMENT REQUIRED: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-12-99 > Apr > 99 > Center Console/Armrest Cover Will Not Latch > Page 6081 3/8 in. Drill Bit 7/32 in. Drill Bit 11/64 in. Drill Bit Rivet Gun POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-41-36-90 0.3 Hrs. FAILURE CODE: P8 - New Part 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. With the center console/armrest down, lid open, and the bezel removed, drill the head of the two latch rivets with a 3/8 in. drill bit until the head of the rivet detaches from the rivet. NOTE: DO NOT DRILL INTO THE LATCH BRACKET. ONLY DRILL THE HEAD OF THE RIVET OFF. 2. Remove the latch assembly. 3. Using the 7/32 in. drill bit, drill the rivet until the rivet is flush with the steel frame. 4. Using the 11/64 in. drill bit, drill the remaining portion of the rivet until the rivet is just behind the steel bin frame. 5. Using an awl or similar object, maneuver the remaining portion of the rivet rearward and to the side behind the steel bin frame until the rivet is out of visible sight. NOTE: IN ORDER TO FREE THE RIVET FROM THE STEEL FRAME, IT MAY BE NECESSARY TO DRIVE THE RIVET TO THE SIDE USING A MALLET AND A PUNCH/AWL. TO PREVENT STRESS MARKS FROM OCCURRING ON THE INTERIOR OF THE CENTER CONSOLE/ARMREST BIN WALL, DO NOT PUSH OR HIT THE RIVET TOO HARD. 6. Clean all metal filings from the center console/armrest latch area. 7. Align the holes of the new latch assembly from kit p/n 05015638AA with the holes located on the steel bin frame. 8. Using a rivet gun and the two rivets supplied in the kit, secure the latch assembly. 9. Place the new latch button into position, then install the new latch cover bezel. Secure the latch cover bezel with the two screws. 10. Verify latch operation by latching and unlatching the lid and cycling the lid through the full range of lid motion. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-02-99 > Jan > 99 > Center Armrest - Lid Rattles Arm Rest: All Technical Service Bulletins Center Armrest - Lid Rattles NUMBER: 23-02-99 GROUP: Body DATE: Jan. 29, 1999 SUBJECT: Center Armrest Lid Rattles OVERVIEW: This bulletin involves installing a stop bumper on the center armrest's striker bezel. MODELS: 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 40-20-40 FRONT SEAT (SALES CODE CBE) BUILT BETWEEN MARCH 23, 1998 (MDH 0328XX) AND OCTOBER 17, 1998 (MDH 1016XX). SYMPTOM/CONDITION: Center armrest lid rattles. DIAGNOSIS: With the center armrest in the down position and the lid latched, tap on the lid directly above the striker and listen for the lid to rattle. If the lid rattles, perform the Repair Procedure. PARTS REQUIRED: 1 05015588AA Stop Bumper Kit Consisting Of: 1 Screw 1 Bumper 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. Open the center armrest cover. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-02-99 > Jan > 99 > Center Armrest - Lid Rattles > Page 6086 2. Remove the driver side screw that attaches the striker bezel to the underside of the armrest cover (Figure 1). 3. Insert the new screw from bumper kit p/n 05015588AA into the new stop bumper. Then. install the stop bumper screw assembly into the location where the screw was removed in Step 2. 4. Verify that the center armrest cover closes easily and that the rattle is gone. If the center armrest cover is difficult to close, the armrest cover can be carefully bent up at the ends (in the direction of a smile) to adjust the tension between the stop bumper and the cover. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-14-21-91 0.2 Hrs. FAILURE CODE: PS - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Center Seat Armrest / Console > Page 6089 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Specifications Ash Tray: Specifications Tighten the two screws that secure the ash receiver flame shield to the instrument panel lower bezel to 2.2 Nm (20 in.lbs). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Specifications > Page 6093 Instrument Panel Ash Receiver Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Specifications > Page 6094 Ash Tray: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Specifications > Page 6095 Ash Tray: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Ash Receiver ....................................................................................................................................... ................................................................... 161 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Specifications > Page 6096 Ash Tray: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the instrument panel ash receiver. 3. Depress the spring retainer in the center of the open ash receiver to release it, then lift the ash receiver slightly and pull it straight out from the pivot pins in the instrument panel lower bezel. Instrument Panel Ash Receiver Remove/Install 4. Remove the two screws that secure the ash receiver flame shield to the instrument panel lower bezel. 5. Pull the ash receiver flame shield out from the instrument panel far enough to disengage the two retaining tabs on the top of the shield from the mounting holes in the instrument panel lower bezel. 6. Lower the flame shield from the instrument panel lower bezel far enough to access the ash receiver lamp and hood. 7. Squeeze the ash receiver lamp and hood bracket to disengage the unit from the mounting hole in the flame shield. 8. Remove the ash receiver flame shield from the instrument panel lower bezel. INSTALLATION 1. Position the ash receiver flame shield to the instrument panel lower bezel. 2. Squeeze the ash receiver lamp and hood bracket and engage the unit to the mounting hole in the flame shield. 3. Insert the two retaining tabs on the top of the ash receiver flame shield into the mounting holes in the instrument panel lower bezel, then push the shield forward to engage the tabs with the bezel. 4. Install and tighten the two screws that secure the ash receiver flame shield to the instrument panel lower bezel. Tighten the screws to 2.2 Nm (20 in.lbs). 5. Align the pivot receptacles on each side of the ash receiver with the pivot pins in the instrument panel lower bezel. 6. Push the ash receiver forward onto the pivot pins in the instrument panel lower bezel until the spring retainer in the center of the open ash receiver snaps into place. 7. Reconnect the battery negative cable Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Front Carpet > Page 6101 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-006-01 > Apr > 01 > Center Armrest/Console - Binds/Sticks Console: 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-006-01 > Apr > 01 > Center Armrest/Console - Binds/Sticks > Page 6110 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch Technical Service Bulletin # 23-32-99 Date: 990827 Center Console/Armrest Lid - Hard To Latch NUMBER: 23-32-99 GROUP: Body EFFECTIVE DATE: Aug. 27, 1999 SUBJECT: Center Console/Armrest Lid Hinge Is Bent OVERVIEW: This bulletin involves replacing the center console/armrest lid. MODELS: 1998 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 40/20/40 SPLIT BENCH FRONT SEAT (EQUIPPED WITH THE FRONT CENTER CONSOLE/ARMREST) BUILT AFTER OCTOBER 13, 1997 (MDH 1O13XX). SYMPTOM/CONDITION: The center console/armrest lid difficult to latch due to a bent lid hinge. DIAGNOSIS: 1. Place the center console/armrest in the down position. 2. Open and close the center console/armrest lid. Proceed to the next step if the center console/armrest lid does not latch when closed. 3. Check the alignment of the lid with the console by looking for witness marks on the latch cover bezel (Figure 1) that may have been caused by the striker coming in contact with the bezel. If there are witness marks on the latch cover bezel, perform the Repair Procedure. If there are no witness marks on the latch cover bezel but the lid does not latch properly, perform Technical Service Bulletin 23-12-99, dated April 23, 1999. PARTS REQUIRED: AR (1) 05016751AA Lid, Center Console/Armrest, Agate AR (1) 05016754AA Lid, Center Console/Armrest, Mist Gray AR (1) 05016755AA Lid, Center Console/Armrest, Camel 1 04883611AA Bezel, Latch Cover POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6115 Labor Operation No: 23-14-15-94 0.2 Hrs. FAILURE CODE: 8 - New Part 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. Place the center console/armrest in the down position. 2. Open the center console/armrest lid to the full open position. 3. Remove the two hinge cover attachment screws from the hinge lid (Figure 2). 4. Close the armrest lid and remove the hinge cover. 5. Move the seats to the full forward position. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6116 6. Using a hammer, carefully tap the hinge pin until the pin is flush with the hinge (Figure 3). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6117 7. Once the hinge pin is flush, open the lid, then insert the steel rod (supplied in the kit) into the hinge and continue tapping (Figure 4.) until the hinge pin is flush with the console portion of the hinge and the lid pops to one side (Figure 5). WARNING: THE LONG LEG OF THE CENTER CONSOLE/ARMREST LID SPRING WILL POP OUT OF THE LID WHILE THE HINGE PIN IS BEING REMOVED. TAKE CARE TO KEEP CLEAR OF THE SPRING LEG WHEN REMOVING THE HINGE PIN FROM THE LID. 8. With the lid to the side, continue driving the hinge pin from the center console/armrest assembly until the hinge pin is free from the assembly (Figure 6). NOTE: THE SUPPLIED STEEL ROD IS DESIGNED TO PROPERLY RETAIN THE HINGE LID SPRING DURING ASSEMBLY. DO NOT REMOVE THE STEEL ROD UNTIL THE NEW LID IS IN PLACE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6118 9. Remove the lid. 10. Engage the long leg of the center console/armrest lid spring into the hole of the new lid) see Parts Required section) (Figure 7). 11. Start the hinge pin into the new lid. With the lid in the upright position, align the lid hinges with the hinges of the lower portion of the console /armrest. Then, slide the hinge pin through the hinge (Figure 8). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6119 12. Close the lid (Figure 9) then, finish installing the hinge pin by tapping it lightly with a hammer until the hinge pin has secured the lid to the console . 13. Continue installing the hinge pin until the pin is positioned as shown in Figure 10. 14. Attach the hinge cover. 15. Open the center console/armrest lid and install the two screws that secure the hinge cover to the center console/armrest lid (Figure 2). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6120 16. Remove the two screws attaching the latch cover bezel (Figure 11), and then remove the latch cover bezel. 17. Install a new latch cover bezel onto the center console. Secure the bezel with the two screws. 18. Close the lid. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-12-99 > Apr > 99 > Center Console/Armrest Cover - Will Not Latch Technical Service Bulletin # 23-12-99 Date: 990423 Center Console/Armrest Cover - Will Not Latch NUMBER: 23-12-99 GROUP: Body DATE: April 23, 1999 SUBJECT: Center Console/Armrest Cover Will Not Latch OVERVIEW: This bulletin involves removing and installing a new center console/armrest latch assembly. MODELS: 1998 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 40/20/40 SPLIT BENCH FRONT SEAT (EQUIPPED WITH THE FRONT CENTER CONSOLE/ARMREST) BUILT AFTER OCTOBER 13, 1997 (MDH 1O13XX). SYMPTOM/CONDITION: Center console/armrest will not latch. DIAGNOSIS: 1. Place the center console/armrest in the down position. 2. Open and close the center console/armrest. Proceed to the next step it the center console/armrest does not latch when closed. 3. Open the center console/armrest lid and remove the two screws attaching the latch bezel cover (Figure 1), then remove the latch cover bezel and latch button. 4. Check the alignment of the lid latch striker with the latch for proper alignment. If the striker and latch do not mate properly, the lid hinge is probably sprung and will require replacement. If the latch and striker line up properly, perform the Repair Procedure. PARTS REQUIRED: 1 05015638AA Center Console/Armrest Latch Repair Kit Includes: (1) Latch Assembly (2) Rivets (1) Latch Button (1) Latch Bezel EQUIPMENT REQUIRED: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-12-99 > Apr > 99 > Center Console/Armrest Cover - Will Not Latch > Page 6125 3/8 in. Drill Bit 7/32 in. Drill Bit 11/64 in. Drill Bit Rivet Gun POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-41-36-90 0.3 Hrs. FAILURE CODE: P8 - New Part 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. With the center console/armrest down, lid open, and the bezel removed, drill the head of the two latch rivets with a 3/8 in. drill bit until the head of the rivet detaches from the rivet. NOTE: DO NOT DRILL INTO THE LATCH BRACKET. ONLY DRILL THE HEAD OF THE RIVET OFF. 2. Remove the latch assembly. 3. Using the 7/32 in. drill bit, drill the rivet until the rivet is flush with the steel frame. 4. Using the 11/64 in. drill bit, drill the remaining portion of the rivet until the rivet is just behind the steel bin frame. 5. Using an awl or similar object, maneuver the remaining portion of the rivet rearward and to the side behind the steel bin frame until the rivet is out of visible sight. NOTE: IN ORDER TO FREE THE RIVET FROM THE STEEL FRAME, IT MAY BE NECESSARY TO DRIVE THE RIVET TO THE SIDE USING A MALLET AND A PUNCH/AWL. TO PREVENT STRESS MARKS FROM OCCURRING ON THE INTERIOR OF THE CENTER CONSOLE/ARMREST BIN WALL, DO NOT PUSH OR HIT THE RIVET TOO HARD. 6. Clean all metal filings from the center console/armrest latch area. 7. Align the holes of the new latch assembly from kit p/n 05015638AA with the holes located on the steel bin frame. 8. Using a rivet gun and the two rivets supplied in the kit, secure the latch assembly. 9. Place the new latch button into position, then install the new latch cover bezel. Secure the latch cover bezel with the two screws. 10. Verify latch operation by latching and unlatching the lid and cycling the lid through the full range of lid motion. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-006-01 > Apr > 01 > Center Armrest/Console Binds/Sticks Console: 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-006-01 > Apr > 01 > Center Armrest/Console Binds/Sticks > Page 6131 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch Technical Service Bulletin # 23-32-99 Date: 990827 Center Console/Armrest Lid - Hard To Latch NUMBER: 23-32-99 GROUP: Body EFFECTIVE DATE: Aug. 27, 1999 SUBJECT: Center Console/Armrest Lid Hinge Is Bent OVERVIEW: This bulletin involves replacing the center console/armrest lid. MODELS: 1998 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 40/20/40 SPLIT BENCH FRONT SEAT (EQUIPPED WITH THE FRONT CENTER CONSOLE/ARMREST) BUILT AFTER OCTOBER 13, 1997 (MDH 1O13XX). SYMPTOM/CONDITION: The center console/armrest lid difficult to latch due to a bent lid hinge. DIAGNOSIS: 1. Place the center console/armrest in the down position. 2. Open and close the center console/armrest lid. Proceed to the next step if the center console/armrest lid does not latch when closed. 3. Check the alignment of the lid with the console by looking for witness marks on the latch cover bezel (Figure 1) that may have been caused by the striker coming in contact with the bezel. If there are witness marks on the latch cover bezel, perform the Repair Procedure. If there are no witness marks on the latch cover bezel but the lid does not latch properly, perform Technical Service Bulletin 23-12-99, dated April 23, 1999. PARTS REQUIRED: AR (1) 05016751AA Lid, Center Console/Armrest, Agate AR (1) 05016754AA Lid, Center Console/Armrest, Mist Gray AR (1) 05016755AA Lid, Center Console/Armrest, Camel 1 04883611AA Bezel, Latch Cover POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6136 Labor Operation No: 23-14-15-94 0.2 Hrs. FAILURE CODE: 8 - New Part 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. Place the center console/armrest in the down position. 2. Open the center console/armrest lid to the full open position. 3. Remove the two hinge cover attachment screws from the hinge lid (Figure 2). 4. Close the armrest lid and remove the hinge cover. 5. Move the seats to the full forward position. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6137 6. Using a hammer, carefully tap the hinge pin until the pin is flush with the hinge (Figure 3). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6138 7. Once the hinge pin is flush, open the lid, then insert the steel rod (supplied in the kit) into the hinge and continue tapping (Figure 4.) until the hinge pin is flush with the console portion of the hinge and the lid pops to one side (Figure 5). WARNING: THE LONG LEG OF THE CENTER CONSOLE/ARMREST LID SPRING WILL POP OUT OF THE LID WHILE THE HINGE PIN IS BEING REMOVED. TAKE CARE TO KEEP CLEAR OF THE SPRING LEG WHEN REMOVING THE HINGE PIN FROM THE LID. 8. With the lid to the side, continue driving the hinge pin from the center console/armrest assembly until the hinge pin is free from the assembly (Figure 6). NOTE: THE SUPPLIED STEEL ROD IS DESIGNED TO PROPERLY RETAIN THE HINGE LID SPRING DURING ASSEMBLY. DO NOT REMOVE THE STEEL ROD UNTIL THE NEW LID IS IN PLACE. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6139 9. Remove the lid. 10. Engage the long leg of the center console/armrest lid spring into the hole of the new lid) see Parts Required section) (Figure 7). 11. Start the hinge pin into the new lid. With the lid in the upright position, align the lid hinges with the hinges of the lower portion of the console /armrest. Then, slide the hinge pin through the hinge (Figure 8). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6140 12. Close the lid (Figure 9) then, finish installing the hinge pin by tapping it lightly with a hammer until the hinge pin has secured the lid to the console . 13. Continue installing the hinge pin until the pin is positioned as shown in Figure 10. 14. Attach the hinge cover. 15. Open the center console/armrest lid and install the two screws that secure the hinge cover to the center console/armrest lid (Figure 2). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-32-99 > Aug > 99 > Center Console/Armrest Lid - Hard To Latch > Page 6141 16. Remove the two screws attaching the latch cover bezel (Figure 11), and then remove the latch cover bezel. 17. Install a new latch cover bezel onto the center console. Secure the bezel with the two screws. 18. Close the lid. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-12-99 > Apr > 99 > Center Console/Armrest Cover Will Not Latch Technical Service Bulletin # 23-12-99 Date: 990423 Center Console/Armrest Cover - Will Not Latch NUMBER: 23-12-99 GROUP: Body DATE: April 23, 1999 SUBJECT: Center Console/Armrest Cover Will Not Latch OVERVIEW: This bulletin involves removing and installing a new center console/armrest latch assembly. MODELS: 1998 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 40/20/40 SPLIT BENCH FRONT SEAT (EQUIPPED WITH THE FRONT CENTER CONSOLE/ARMREST) BUILT AFTER OCTOBER 13, 1997 (MDH 1O13XX). SYMPTOM/CONDITION: Center console/armrest will not latch. DIAGNOSIS: 1. Place the center console/armrest in the down position. 2. Open and close the center console/armrest. Proceed to the next step it the center console/armrest does not latch when closed. 3. Open the center console/armrest lid and remove the two screws attaching the latch bezel cover (Figure 1), then remove the latch cover bezel and latch button. 4. Check the alignment of the lid latch striker with the latch for proper alignment. If the striker and latch do not mate properly, the lid hinge is probably sprung and will require replacement. If the latch and striker line up properly, perform the Repair Procedure. PARTS REQUIRED: 1 05015638AA Center Console/Armrest Latch Repair Kit Includes: (1) Latch Assembly (2) Rivets (1) Latch Button (1) Latch Bezel EQUIPMENT REQUIRED: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-12-99 > Apr > 99 > Center Console/Armrest Cover Will Not Latch > Page 6146 3/8 in. Drill Bit 7/32 in. Drill Bit 11/64 in. Drill Bit Rivet Gun POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-41-36-90 0.3 Hrs. FAILURE CODE: P8 - New Part 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. With the center console/armrest down, lid open, and the bezel removed, drill the head of the two latch rivets with a 3/8 in. drill bit until the head of the rivet detaches from the rivet. NOTE: DO NOT DRILL INTO THE LATCH BRACKET. ONLY DRILL THE HEAD OF THE RIVET OFF. 2. Remove the latch assembly. 3. Using the 7/32 in. drill bit, drill the rivet until the rivet is flush with the steel frame. 4. Using the 11/64 in. drill bit, drill the remaining portion of the rivet until the rivet is just behind the steel bin frame. 5. Using an awl or similar object, maneuver the remaining portion of the rivet rearward and to the side behind the steel bin frame until the rivet is out of visible sight. NOTE: IN ORDER TO FREE THE RIVET FROM THE STEEL FRAME, IT MAY BE NECESSARY TO DRIVE THE RIVET TO THE SIDE USING A MALLET AND A PUNCH/AWL. TO PREVENT STRESS MARKS FROM OCCURRING ON THE INTERIOR OF THE CENTER CONSOLE/ARMREST BIN WALL, DO NOT PUSH OR HIT THE RIVET TOO HARD. 6. Clean all metal filings from the center console/armrest latch area. 7. Align the holes of the new latch assembly from kit p/n 05015638AA with the holes located on the steel bin frame. 8. Using a rivet gun and the two rivets supplied in the kit, secure the latch assembly. 9. Place the new latch button into position, then install the new latch cover bezel. Secure the latch cover bezel with the two screws. 10. Verify latch operation by latching and unlatching the lid and cycling the lid through the full range of lid motion. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Page 6147 Console: Specifications Tighten the screw that secures the front of the overhead console housing to the overhead console bracket to 1.9 Nm (17 in. lbs.). Tighten the two screws that secure the front of the overhead console bracket to the roof front header to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Page 6148 Overhead Console Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions Console: Diagram Information and Instructions Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6151 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6152 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6153 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6154 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6155 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6156 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6157 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6158 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6159 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6160 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6161 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6162 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6163 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6164 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6165 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6166 Console: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6167 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6168 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 6169 Console: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Overhead Console ............................................................................................................................... ................................................................ 212-2 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 6170 Console: Description and Operation DESCRIPTION Overhead Console System 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 a 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. Overhead Console Overhead Console The overhead console for this model includes two front-mounted reading and courtesy lamps, a garage door opener storage bin, a sunglasses storage bin and a 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. See the owner's manual in the vehicle glove box for more information on the use and operation of the various overhead console features. 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 module. The ambient temperature sensor is available as a separate service item. Sunglasses 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 6171 Operation 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 spring-loaded 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Procedures Console: Procedures Overhead Console Replacement REMOVAL Overhead Console 1. Disconnect and isolate the battery negative cable. Overhead Console Remove/Install 2. Remove the screw that secures the front of the overhead console to the front of the overhead console bracket. 3. Insert the fingertips of both hands between the headliner and the sides of the overhead console housing in the area between the garage door opener storage bin and the sunglasses storage bin. 4. Pull downward on the sides of the overhead console housing firmly and evenly to disengage the two snap clips that secure the rear of the unit from their receptacles in the overhead console bracket. 5. Lower the overhead console from the headliner far enough to access the wire harness connector. 6. Disconnect the roof wire harness connector from the overhead console wire harness connector. 7. Remove the overhead console from the headliner. Overhead Console Bracket 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console from the overhead console bracket. Refer to Overhead Console/Service and Repair for the procedures. 3. Remove the headliner from the roof panel. Overhead Console Bracket Remove/Install 4. Remove the two screws that secure the front of the overhead console bracket to the roof front header. 5. Using a sharp utility knife, cut through the double-faced tape that secures the rear flange of the overhead console bracket to the roof panel. 6. Remove the overhead console bracket from the roof panel. INSTALLATION Overhead Console 1. Position the overhead console near the mounting location on the headliner. 2. Reconnect the roof wire harness connector to the overhead console wire harness connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Procedures > Page 6174 3. Align the locating pin on the rear of the overhead console housing with the receptacle in the rear of the overhead console bracket. 4. Align the two snap clips on the overhead console housing with their receptacles in the overhead console bracket. 5. Push upward firmly and evenly on the sides of the overhead console housing over both of the snap clip locations until each of the two snap clips is fully engaged with its receptacle in the overhead console bracket. 6. Install and tighten the screw that secures the front of the overhead console housing to the overhead console bracket. Tighten the screw to 1.9 Nm (17 in. lbs.). 7. Reconnect the battery negative cable. Overhead Console Bracket 1. Remove any remnants of the old double-faced tape from the roof panel and the rear flange of the overhead console bracket and clean these areas with a suitable solvent to remove any traces of grease, oil or adhesive residue. When installing the overhead console bracket, always apply a new piece of double- faced tape to the rear flange of the bracket. 2. Align the two locating pins on the front of the overhead console bracket with the receptacles in the roof front header. 3. Lower the rear flange of the overhead console bracket from the roof panel far enough to access and remove the release paper from the double-faced tape. 4. Push upward firmly and evenly on the rear flange of the overhead console bracket over the double-faced tape to ensure complete adhesion to the roof panel. 5. Install and tighten the two screws that secure the front of the overhead console bracket to the roof front header. Tighten the screws to 2.2 Nm (20 in. lbs.). 6. Install the headliner onto the roof panel. 7. Install the overhead console onto the overhead console bracket. Refer to Overhead Console/Service and Repair for the procedures. 8. Reconnect the battery negative cable. Sunglasses Storage Bin Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the reading and courtesy lamp housing from the overhead console. Refer to Overhead Console Reading and Courtesy Lamp Housing/Service and Repair for the procedures. 3. Unlatch and remove the sunglasses storage bin from the overhead console housing. INSTALLATION 1. Position the sunglasses storage bin into the overhead console housing. 2. Engage the latch of the sunglasses storage bin with the latch striker on the rear of the storage bin opening in the overhead console housing. 3. Be certain that the sunglasses storage bin pivot shaft is located in the two pivot receptacles just behind the reading and courtesy lamp lenses in the overhead console housing. 4. Be certain that the sunglasses storage bin damper spring is installed on the pivot shaft with the two end tabs of the spring engaged with the flats on the rear of the shaft, and the center tab engaged over the front of the shaft. 5. Install the reading and courtesy lamp housing onto the overhead console. Refer to Overhead Console Reading and Courtesy Lamp Housing/Service and Repair for the procedures. 6. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Procedures > Page 6175 Console: Removal and Replacement 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. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Procedures > Page 6176 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. Floor Console FLOOR CONSOLE REMOVAL Fig. 11 1. Using a small flat blade, remove forward and rearward rubber inserts (Fig. 11). 2. Remove bolts attaching floor console to floor pan. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Procedures > Page 6177 3. Disconnect electrical connector. 4. Remove the console. INSTALLATION 1. Connect electrical connector. 2. Position the locator tabs and install the console. 3. Install the seven bolts and tighten to 5 N.m (45 in. lbs.). 4. Install the rubber inserts into the console. Mini Floor Console MINI FLOOR CONSOLE REMOVAL Fig. 12 1. Remove the rubber mats (Fig. 12). 2. Remove the bolts and remove the console. INSTALLATION 1. Position the locator tab and install the console. 2. Install the three bolts and tighten to 5 N.m (45 in. lbs.). 3. Install the rubber console mats. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Page 6178 Degaussing Tool 6029 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming Disconnect and isolate the battery negative cable. If the airbag module has not been deployed, wait two minutes for the system capacitor to discharge before further service. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 6184 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming 16-Way Data Link Connector - Typical 1. Make sure no one is in the vehicle. 2. Connect the negative battery terminal. 3. Connect the DRB scan tool to the 16-way data link wire harness connector. The connector is located on the driver side lower edge of the instrument panel, outboard of the steering column. 4. Turn the ignition switch to the ON position. Exit the vehicle with the DRB. Use the latest version of the proper DRB cartridge. 5. Erase the stored DTC data. If any problems remain, the stored DTC data will not erase. 6. With the ignition switch still in the ON position, make sure nobody is in the vehicle. 7. From outside of the vehicle (away from the airbag modules in case of an accidental deployment) turn the ignition switch to the OFF position for about 10 seconds, and then back to the ON position. Observe the airbag indicator lamp in the instrument cluster. It should light for six to 8 seconds, and then go out. This indicates that the airbag system is functioning normally. NOTE: If the airbag indicator lamp fails to light, or lights and stays on, there is an airbag system malfunction. Refer to the proper Diagnostic Procedures to diagnose the problem. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock > Component Information > Service and Repair Glove Compartment Lock: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. Glove Box Latch Striker Remove/Install 3. Remove the two screws that secure the latch striker to the instrument panel glove box opening upper reinforcement. 4. Remove the latch striker from the instrument panel glove box opening upper reinforcement. INSTALLATION 1. Position the latch striker onto the instrument panel glove box opening upper reinforcement. 2. Install and tighten the two screws that secure the latch striker to the instrument panel glove box opening upper reinforcement. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Close the glove box. 4. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 6192 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Page 6202 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures Trim Panel: Procedures 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.19 Door Trim Panel Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6207 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 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6208 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. Rear Door Trim Panel REAR DOOR TRIM PANEL REMOVAL 1. Release door latch and open door. 2. Roll window down. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6209 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6210 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. Heat Staking 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6211 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6212 Trim Panel: Removal and Replacement 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. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6213 B-Pillar Trim B-PILLAR TRIM REMOVAL 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6214 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. Cowl Trim Cover 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6215 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6216 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. Door Sill Trim 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 Fig. 9 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6217 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. Liftgate Opening Upper Trim LIFTGATE OPENING UPPER TRIM 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Rear Storage Box > Page 6222 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Description and Operation Keyless Entry Receiver: Description and Operation SYSTEM OPERATION The Remote Keyless Entry (RKE) receiver is a radio frequency unit that is integral to the high-line version of the Central Timer Module (CTM). The CTM also contains the program logic and control circuitry for the RKE system. The CTM is mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. The RKE receiver has a memory function to retain the vehicle access codes of up to four RKE transmitters. The receiver is designed to retain the transmitter codes in memory, even if the battery is disconnected. The RKE receiver is energized by one of three radio frequency inputs from the RKE transmitter; Unlock, Lock, or Panic. The programming of the CTM responds to these RKE inputs, as well as many other inputs, by sending the proper control outputs to the power lock motors, the courtesy lamp circuit, the driver unlock relay, the horn relay, and the headlamp relay For diagnosis or programming of the RKE receiver within the high-line CTM, a DRB scan tool and the proper Diagnostic Procedures are recommended. The RKE receiver is only serviced as a unit with the high-line CTM and, if faulty or damaged, the CTM unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 another suitable wide flat-bladed tool, gently pry at the center seam of the transmitter case halves near the key ring until the two halves unsnap. 2. Lift the back half of the transmitter case off of the transmitter. 3. Remove the two batteries from the 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 transmitter case halves with each other, and squeeze them firmly together until they snap back into place. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Specifications Power Door Lock Actuator: Specifications Power Lock Motor Mounting Screws 30 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Specifications > Page 6240 Power Door Lock Actuator: Description and Operation SYSTEM OPERATION In the power lock and Remote Keyless Entry (RKE) systems, the door and liftgate latch lock mechanisms can be actuated by a reversible electric motor. The power lock motor is integral to the door latch mounted within each door. A separate power lock motor is used to actuate the liftgate latch. The power lock motor direction is controlled by the battery and ground feeds from the power lock and unlock relays, which are integral to the high-line Central Timer Module (CTM). The RKE receiver within the CTM can also unlock just the driver door through a separate driver door unlock relay that is located in the relay and fuse block attached to the back of the junction block under the instrument panel. The power door lock motors cannot be repaired and, if faulty or damaged, the entire door latch unit must be replaced. The power liftgate lock motor is serviced separately. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Specifications > Page 6241 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. See Diagnosis and Testing. 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. Unplugging a shorted power lock motor from the power lock circuit will allow the good power lock motor to operate. Unplug each power lock motor wire harness connector, 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 unplugging one power lock motor causes the other motor to become functional, go to Step 3 to test the unplugged motor. 3. Once it is determined which power lock motor is inoperative, that motor can be tested as follows. Unplug the wire harness connector at the inoperative power lock motor. Apply 12 volts to the motor terminals to check its operation in one direction. Reverse the polarity to check the operation in the other direction. If OK, repair the short or open circuits between the power lock motor and the CTM as required. If not OK, replace the faulty power lock motor. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Specifications > Page 6242 Power Door Lock Actuator: Service and Repair REMOVAL Door The power lock motor is integral to the door latch unit. If the power lock motor is faulty or damaged, the entire door latch unit must be replaced. Liftgate 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inner liftgate panel. 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 unplug the wire harness connector. 5. Lower the power lock motor far enough to access and disengage the link from the liftgate latch clip. 6. Remove the power lock motor from the liftgate. 7. Reverse the removal procedures to install. Tighten the mounting screws to 3.3 Nm (30 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations 8w-11-002 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 6246 Power Door Lock Relay: Diagrams Relay And Fuse Box Driver Unlock Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 6247 Power Door Lock Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 6248 Power Door Lock Relay: Description and Operation SYSTEM DESCRIPTION The driver unlock relay is a 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The driver unlock relay is a electromechanical device that switches battery current to the left front door power lock motor when the Remote Keyless Entry (RKE) receiver within the high-line Central Timer Module (CTM) grounds the relay coil. Test the Driver Unlock Relay. The driver unlock relay is located in the relay and fuse block attached to the back of the junction block, under the left side of the instrument panel in the passenger compartment. The driver unlock relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 6249 Power Door Lock Relay: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover and knee blocker from the instrument panel. Refer to Steering Column Opening Cover and Knee Blocker/Service and Repair for the procedures. Relay And Fuse Block 3. Reach through the outboard side of the steering column opening in the instrument panel to access the relay and fuse block on the back of the junction block. 4. Unplug the driver unlock relay from the relay and fuse block. 5. Install the driver unlock relay by aligning the relay terminals with the cavities in the relay and fuse block and pushing the relay firmly into place. 6. Connect the battery negative cable. 7. Test the relay operation. 8. Reverse the remaining removal procedures to complete the installation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Specifications Power Door Lock Switch: Specifications Power Lock Switch Mounting Screws 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Specifications > Page 6253 Driver Power Window/Door Lock Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Specifications > Page 6254 Power Door Lock Switch: Description and Operation SYSTEM OPERATION The power locks can be controlled by a two-way switch integral to the power window and lock switch unit on the driver side front door trim panel, or a two-way single gang switch on the passenger side front door trim panel. The power lock switch controls the battery feeds to the lock and unlock sense inputs of the high-line Central Timer Module (CTM). The CTM then relays the correct battery and ground feeds to the power lock motors. A Light-Emitting Diode (LED) in the paddle of each switch is illuminated whenever the ignition switch is in the On position. The driver side power window and lock switch unit cannot be repaired and, if faulty or damaged, the entire switch unit must be replaced. The passenger side power lock switch cannot be repaired and, if faulty or damaged, the switch must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Specifications > Page 6255 Power Door Lock Switch: Testing and Inspection If the problem being diagnosed involves only the power lock switch illumination LEDs, check the fused ignition switch output (run) and ground circuits at the power lock switch connector. 1. Check the 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. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Unplug the wire harness connector from the power lock switch. 4. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the body half of the power lock switch wire harness connector. If OK, go to Step 5. If not OK, repair the open circuit to the junction block as required. Power Lock Switch Continuity - Driver Side Power Lock Switch Continuity - Passenger Side 5. Test the power lock switch continuity See the Power Lock Switch Continuity charts to determine if the continuity is correct in the Off, Lock and Unlock switch positions. If OK, repair the door lock switch output (lock Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Specifications > Page 6256 and/or unlock) circuit(s) from the body half of the power lock switch wire harness connector to the Central Timer Module (CTM) as required. If not OK, replace the faulty switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Specifications > Page 6257 Power Door Lock Switch: Service and Repair REMOVAL Driver Side Front Door 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the driver side front door. 3. From the back side of the trim panel, remove the screws that secure the power window and lock switch unit to the switch bezel in the door trim panel opening. 4. Remove the power window and lock switch and the switch bezel from the door trim panel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Passenger Side Front Door 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the passenger side front door. 3. With a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power window switch receptacle on the back of the door trim panel switch bezel and pull the switch out of the receptacle. 4. Reverse the removal procedures to install. Be certain that both of the switch snap retainers in the receptacle on the back of the door trim panel switch bezel are fully engaged. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations Power Mirror Switch Knob Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 6265 Power Mirror Switch: Description and Operation SYSTEM DESCRIPTION Both the right and left power outside mirrors are controlled by a single multi-function switch unit located on and mounted to the upper flag area of the driver side door trim panel. The switch knob is rotated clockwise (right mirror control), or counterclockwise (left mirror control) to select the mirror to be adjusted. The switch knob is then moved in a joystick fashion to control movement of the selected mirror up, down, right, or left. The power mirror switch cannot be repaired and, if faulty or damaged, it must be replaced. The power mirror switch knob is available for service replacement. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 6266 Power Mirror Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Mirror Switch Knob Remove/Install 2. Pull the power mirror switch control knob rearward to remove it from the switch stem. Power Mirror Switch Nut 3. Remove the nut that secures the power mirror switch to the driver side door trim panel. 4. Remove the trim panel from the inside of the driver side front door. 5. Pull the trim panel away from the inner door panel far enough to access the power mirror switch wire harness connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 6267 Door Trim Panel Wire Harness Connectors 6. Unplug the power mirror switch wire harness connector. 7. Remove the power mirror switch from the back of the door trim panel. 8. Reverse the removal procedures to install. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Page 6272 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations 8w-11-002 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 6277 Power Door Lock Relay: Diagrams Relay And Fuse Box Driver Unlock Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 6278 Power Door Lock Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 6279 Power Door Lock Relay: Description and Operation SYSTEM DESCRIPTION The driver unlock relay is a 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The driver unlock relay is a electromechanical device that switches battery current to the left front door power lock motor when the Remote Keyless Entry (RKE) receiver within the high-line Central Timer Module (CTM) grounds the relay coil. Test the Driver Unlock Relay. The driver unlock relay is located in the relay and fuse block attached to the back of the junction block, under the left side of the instrument panel in the passenger compartment. The driver unlock relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 6280 Power Door Lock Relay: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover and knee blocker from the instrument panel. Refer to Steering Column Opening Cover and Knee Blocker/Service and Repair for the procedures. Relay And Fuse Block 3. Reach through the outboard side of the steering column opening in the instrument panel to access the relay and fuse block on the back of the junction block. 4. Unplug the driver unlock relay from the relay and fuse block. 5. Install the driver unlock relay by aligning the relay terminals with the cavities in the relay and fuse block and pushing the relay firmly into place. 6. Connect the battery negative cable. 7. Test the relay operation. 8. Reverse the remaining removal procedures to complete the installation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6290 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6291 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6292 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6293 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6294 TIME ALLOWANCE: FAILURE CODE: Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Description and Operation Power Seat Motor: Description and Operation SYSTEM OPERATION Power Seat Adjuster And Motors 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 to the Up or Down position, both the front and rear motors operate in unison, moving the entire seat up or down. The forward-rearward motor is operated by pushing the center seat switch to the Forward or Rearward position. When a switch is actuated, a battery feed and a ground path are applied through the switch contacts to the motor(s). The motor(s) and drives operate to move the seat in the selected direction until the switch is released, or until the travel limit of the power seat adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor(s) are reversed through the switch contacts. This causes the motor to run in the opposite direction. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Description and Operation > Page 6301 Power Seat Motor: 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 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 seat adjuster still fails to operate in only one direction, see Power Seat Switch in the Diagnosis and Testing. If the power seat adjuster fails to operate in more than one direction, proceed as follows: 1. Check for battery voltage at the 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. 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 PDC 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. If the switch tests OK, check the wire harness for the inoperative power seat motor(s) between the power seat switch and the motor for shorts or opens. If the circuits check OK, replace the faulty power seat adjuster and motors assembly. If the circuits are not OK, repair the wire harness as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Description and Operation > Page 6302 Power Seat Motor: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side seat, adjuster and motors assembly from the vehicle as a unit. 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 adjuster and motors assembly. 5. Remove the four screws that secure the power seat adjuster and motors assembly to the seat cushion frame. 6. If the vehicle is equipped with a split bench seat, remove the fasteners that secure the center seat cushion to the brackets on the power seat adjuster. 7. Remove the power seat adjuster and motors assembly from the seat cushion frame. CAUTION: Before installing the seat into the vehicle, be certain to adjust the seat fully rearward on its tracks. Then install and tighten the front track mounting screws before installing the rear screws or the tracks may be damaged. 8. Reverse the removal procedures to install. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Specifications Power Seat Switch: Specifications Power Seat Switch Mounting Screws 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Specifications > Page 6306 Power Seat Switch: Locations Power Seat Switch Remove/Install - Typical The switch is located on the lower outboard side of the seat cushion on the seat cushion side shield. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Specifications > Page 6307 Power Seat Switch: Description and Operation SYSTEM OPERATION The power seat can be adjusted in six different ways using the power seat switch. The switch is located on the lower outboard side of the seat cushion on the seat cushion side shield. Refer to the owner's manual for more information on the power seat switch functions and the seat adjusting procedures. The individual switches in the power seat switch unit cannot be repaired. If one switch is damaged or faulty, the entire power seat switch unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Specifications > Page 6308 Power Seat Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Power Seat Switch Continuity 3. Use an ohmmeter to test the continuity of the power seat switches in each position. See the Power Seat Switch Continuity chart. If OK, see Power Seat Adjuster and Motors in the Diagnosis and Testing. If not OK, replace the faulty power seat switch unit. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Specifications > Page 6309 Power Seat Switch: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the driver side front seat. 3. Pull the recliner lever off of the recliner mechanism release shaft. 4. Remove the three screws that secure the driver side seat cushion side shield to the outboard seat cushion frame. 5. Pull the driver side seat cushion side shield away from the seat cushion frame far enough to access the power seat switch module wire harness connector. 6. Unplug the wire harness connector from the power seat switch module. 7. Remove the seat cushion side shield and power seat switch module from the seat as a unit. Power Seat Switch Remove/Install - Typical 8. Remove the two screws that secure the power seat switch to the inside of the seat cushion side shield. 9. Remove the power seat switch from the seat cushion side shield. 10. Reverse the removal procedures to install. Tighten the switch mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest for Seat Back: > 23-31-00 > Aug > 00 > Seat - Rattle/Chuck in Upright Position Seat Back: Customer Interest Seat - Rattle/Chuck in Upright Position NUMBER: 23-31-00 GROUP: Body DATE: August 18, 2000 SUBJECT: Rattle/Chuck In The Second Row Seat When Seat Is In Upright Position OVERVIEW: This bulletin involves installing revised outboard seat back latches on both right side and left side second row seats. MODELS: 1998 - 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 40/20/40 SECOND ROW SPLIT BENCH SEAT (SALES CODE CFM). SYMPTOM/CONDITION: The 40/20/40 second row split bench seat back may chuck or rattle while in the upright and locked position when going over bumps. DIAGNOSIS: With the second row seat latched in the upright position, firmly grab the seat back on the upper outboard corner of either 40% portion of the second row seat and push in a fore-aft motion. If the seat latch rattles when you push the seat back fore and aft, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: This repair is Compatible with Daimler Chrysler's Mobile Service program And does Not Require Hoists or Other Full Service facility special Equipment. 1. Tumble the seat forward. 2. Remove the screw that secures the outboard latch release handle and remove the handle. 3. Remove the three screws that secure the outboard latch cover and remove the latch cover. 4 Disengage the seat cover hook-and-arrow on the outboard side of the seatback (Figure 1). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest for Seat Back: > 23-31-00 > Aug > 00 > Seat - Rattle/Chuck in Upright Position > Page 6318 5. Remove bolts attaching the outboard latch to the seat cushion and seat back frame. 6. Disconnect the cable to the outboard latch. 7. Connect the cable to the new outboard latch (see Parts Required section). 8. Install the new outboard latch onto the seat cushion and seat back frame. Tighten the bolt located in the round hole first, than the bolts located in the slotted holes (Figure 2). Tighten the bolts to 27 N.m (19 ft.lbs.). NOTE: THE SEAT MUST BE IN THE FORWARD TUMBLED POSITION PRIOR TO TIGHTENING THE NEW OUTBOARD LATCH. FAILURE TO TIGHTEN THE LATCH IN THIS POSITION COULD RESULT IN LOOSENESS BETWEEN THE LATCH AND THE SEAT CUSHION FRAME CAUSING A CHUCK/RATTLE IN THE OUTBOARD LATCH. 9. Engage the seat cover hook-and-arrow on the outboard side of the seatback. 10. Install the outboard latch cover and secure it with the three screws. 11. Install the outboard latch release handle and secure it with the screw. 12. Remove and install the second row outboard latch on the other seat using the procedure described in Steps 1 through 11. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 23-31-00 > Aug > 00 > Seat - Rattle/Chuck in Upright Position Seat Back: All Technical Service Bulletins Seat - Rattle/Chuck in Upright Position NUMBER: 23-31-00 GROUP: Body DATE: August 18, 2000 SUBJECT: Rattle/Chuck In The Second Row Seat When Seat Is In Upright Position OVERVIEW: This bulletin involves installing revised outboard seat back latches on both right side and left side second row seats. MODELS: 1998 - 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 40/20/40 SECOND ROW SPLIT BENCH SEAT (SALES CODE CFM). SYMPTOM/CONDITION: The 40/20/40 second row split bench seat back may chuck or rattle while in the upright and locked position when going over bumps. DIAGNOSIS: With the second row seat latched in the upright position, firmly grab the seat back on the upper outboard corner of either 40% portion of the second row seat and push in a fore-aft motion. If the seat latch rattles when you push the seat back fore and aft, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: This repair is Compatible with Daimler Chrysler's Mobile Service program And does Not Require Hoists or Other Full Service facility special Equipment. 1. Tumble the seat forward. 2. Remove the screw that secures the outboard latch release handle and remove the handle. 3. Remove the three screws that secure the outboard latch cover and remove the latch cover. 4 Disengage the seat cover hook-and-arrow on the outboard side of the seatback (Figure 1). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 23-31-00 > Aug > 00 > Seat - Rattle/Chuck in Upright Position > Page 6324 5. Remove bolts attaching the outboard latch to the seat cushion and seat back frame. 6. Disconnect the cable to the outboard latch. 7. Connect the cable to the new outboard latch (see Parts Required section). 8. Install the new outboard latch onto the seat cushion and seat back frame. Tighten the bolt located in the round hole first, than the bolts located in the slotted holes (Figure 2). Tighten the bolts to 27 N.m (19 ft.lbs.). NOTE: THE SEAT MUST BE IN THE FORWARD TUMBLED POSITION PRIOR TO TIGHTENING THE NEW OUTBOARD LATCH. FAILURE TO TIGHTEN THE LATCH IN THIS POSITION COULD RESULT IN LOOSENESS BETWEEN THE LATCH AND THE SEAT CUSHION FRAME CAUSING A CHUCK/RATTLE IN THE OUTBOARD LATCH. 9. Engage the seat cover hook-and-arrow on the outboard side of the seatback. 10. Install the outboard latch cover and secure it with the three screws. 11. Install the outboard latch release handle and secure it with the screw. 12. Remove and install the second row outboard latch on the other seat using the procedure described in Steps 1 through 11. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest for Seat Cover: > 23-51-98 > Oct > 98 > Left Front Leather Seatcover - Chafing Technical Service Bulletin # 23-51-98 Date: 981023 Left Front Leather Seatcover - Chafing NO: 23-51-98 GROUP: Body DATE: Oct. 23, 1998 SUBJECT: Left Front Leather Seat Cover Chaffed From The Plastic Side Shield THIS REPAIR IS COMPATIBLE WITH CHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. MODELS: 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH FRONT LEATHER BUCKET SEATS (SALES CODE LJ) BUILT BEFORE SEP. 3, 1998 (MDH 0903XX). SYMPTOM/CONDITION: Left front leather seat side shield chafes the seat cover. DIAGNOSIS: Inspect the left front seat cover material where the side shield contacts the seat cover for signs of chaffing. If the seat cover is chaffed, perform the Repair Procedure. PARTS REQUIRED: AR (1) OSZ861AZAA Shield, Left Front Seat Side, Agate Trim AR (1) ORX111AZAA Cushion, Left Front Lower Seat Cover And, Agate Trim AR (1) OSZ861C3AA Shield, Left Front Seat Side, Mist Grey Trim AR (1) ORX111C3AA Cushion, Left Front Lower Seat Cover And, Mist Grey Trim AR (1) OSZ861K5AA Shield, Left Front Seat Side, Camel Trim AR (1) ORX111K5AA Cushion, Left Front Lower Seat Cover And, Camel Trim POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-20-40-95 0.6 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the left front lower seat cover and cushion and installing a new side shield. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the power seat harness connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest for Seat Cover: > 23-51-98 > Oct > 98 > Left Front Leather Seatcover - Chafing > Page 6333 3. Remove the anchor bolt attaching the belt to the seat track (Figure 1). 4. Remove the seat. 5. Remove the screw that secures the recliner lever to the seat and separate the lever from the seat. 6. Remove the two screws that secure the side shield to the seat cushion frame. 7. Pull the seat cushion side shield away from the seat far enough to access the power seat switch module. 8. Remove the two screws that secure the power seat switch to the inside of the seat cushion side shield (Figure 2) and separate the switch from the side shield. 9. Disengage the rearward corner J-straps. 10. Disengage both side J-straps. 11. Disengage the front J-strap. 12. Disengage the hook and loop fastener. 13. Separate the cushion and cover from the seat frame. NOTE: MAKE SURE THE PLASTIC ANTI-SQUEAK MAT IS PROPERLY INSTALLED PRIOR TO INSTALLING THE NEW CUSHION AND COVER. 14. Position the new cushion and cover (see Parts Required section) onto the frame. 15. Engage the front J-strap. 16. Engage both side J-straps. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest for Seat Cover: > 23-51-98 > Oct > 98 > Left Front Leather Seatcover - Chafing > Page 6334 17. Engage the rearward J-strap. 18. Engage the hook and loop fasteners. 19. Attach the power seat switch to the new seat side shield (see Parts Required section) with two screws. Tighten the switch to 2.2 Nm (20 in. lbs.). 20. Attach the seat side shield to the seat cushion frame with two screws. 21. Attach the recliner lever onto the seat with the screw. 22. Install the anchor bolt attaching the seat belt to the seat track. Tighten the bolt to 40 Nm (29 ft. lbs.). 23. Install the seat. Tighten the front seat track bolts to 22 - 34 Nm (16 - 25 ft. lbs.). Tighten the rear seat track bolts to 89 - 140 Nm (66 - 103 ft. lbs.). 24. Attach the power seat wire harness connector. 25. Connect the battery negative cable, reset the clock in the radio, and verify Seat operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 23-51-98 > Oct > 98 > Left Front Leather Seatcover - Chafing Technical Service Bulletin # 23-51-98 Date: 981023 Left Front Leather Seatcover - Chafing NO: 23-51-98 GROUP: Body DATE: Oct. 23, 1998 SUBJECT: Left Front Leather Seat Cover Chaffed From The Plastic Side Shield THIS REPAIR IS COMPATIBLE WITH CHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. MODELS: 1998 - 1999 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH FRONT LEATHER BUCKET SEATS (SALES CODE LJ) BUILT BEFORE SEP. 3, 1998 (MDH 0903XX). SYMPTOM/CONDITION: Left front leather seat side shield chafes the seat cover. DIAGNOSIS: Inspect the left front seat cover material where the side shield contacts the seat cover for signs of chaffing. If the seat cover is chaffed, perform the Repair Procedure. PARTS REQUIRED: AR (1) OSZ861AZAA Shield, Left Front Seat Side, Agate Trim AR (1) ORX111AZAA Cushion, Left Front Lower Seat Cover And, Agate Trim AR (1) OSZ861C3AA Shield, Left Front Seat Side, Mist Grey Trim AR (1) ORX111C3AA Cushion, Left Front Lower Seat Cover And, Mist Grey Trim AR (1) OSZ861K5AA Shield, Left Front Seat Side, Camel Trim AR (1) ORX111K5AA Cushion, Left Front Lower Seat Cover And, Camel Trim POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-20-40-95 0.6 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the left front lower seat cover and cushion and installing a new side shield. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the power seat harness connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 23-51-98 > Oct > 98 > Left Front Leather Seatcover - Chafing > Page 6340 3. Remove the anchor bolt attaching the belt to the seat track (Figure 1). 4. Remove the seat. 5. Remove the screw that secures the recliner lever to the seat and separate the lever from the seat. 6. Remove the two screws that secure the side shield to the seat cushion frame. 7. Pull the seat cushion side shield away from the seat far enough to access the power seat switch module. 8. Remove the two screws that secure the power seat switch to the inside of the seat cushion side shield (Figure 2) and separate the switch from the side shield. 9. Disengage the rearward corner J-straps. 10. Disengage both side J-straps. 11. Disengage the front J-strap. 12. Disengage the hook and loop fastener. 13. Separate the cushion and cover from the seat frame. NOTE: MAKE SURE THE PLASTIC ANTI-SQUEAK MAT IS PROPERLY INSTALLED PRIOR TO INSTALLING THE NEW CUSHION AND COVER. 14. Position the new cushion and cover (see Parts Required section) onto the frame. 15. Engage the front J-strap. 16. Engage both side J-straps. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 23-51-98 > Oct > 98 > Left Front Leather Seatcover - Chafing > Page 6341 17. Engage the rearward J-strap. 18. Engage the hook and loop fasteners. 19. Attach the power seat switch to the new seat side shield (see Parts Required section) with two screws. Tighten the switch to 2.2 Nm (20 in. lbs.). 20. Attach the seat side shield to the seat cushion frame with two screws. 21. Attach the recliner lever onto the seat with the screw. 22. Install the anchor bolt attaching the seat belt to the seat track. Tighten the bolt to 40 Nm (29 ft. lbs.). 23. Install the seat. Tighten the front seat track bolts to 22 - 34 Nm (16 - 25 ft. lbs.). Tighten the rear seat track bolts to 89 - 140 Nm (66 - 103 ft. lbs.). 24. Attach the power seat wire harness connector. 25. Connect the battery negative cable, reset the clock in the radio, and verify Seat operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > Customer Interest for Seat Latch: > 23-31-00 > Aug > 00 > Seat - Rattle/Chuck in Upright Position Seat Latch: Customer Interest Seat - Rattle/Chuck in Upright Position NUMBER: 23-31-00 GROUP: Body DATE: August 18, 2000 SUBJECT: Rattle/Chuck In The Second Row Seat When Seat Is In Upright Position OVERVIEW: This bulletin involves installing revised outboard seat back latches on both right side and left side second row seats. MODELS: 1998 - 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 40/20/40 SECOND ROW SPLIT BENCH SEAT (SALES CODE CFM). SYMPTOM/CONDITION: The 40/20/40 second row split bench seat back may chuck or rattle while in the upright and locked position when going over bumps. DIAGNOSIS: With the second row seat latched in the upright position, firmly grab the seat back on the upper outboard corner of either 40% portion of the second row seat and push in a fore-aft motion. If the seat latch rattles when you push the seat back fore and aft, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: This repair is Compatible with Daimler Chrysler's Mobile Service program And does Not Require Hoists or Other Full Service facility special Equipment. 1. Tumble the seat forward. 2. Remove the screw that secures the outboard latch release handle and remove the handle. 3. Remove the three screws that secure the outboard latch cover and remove the latch cover. 4 Disengage the seat cover hook-and-arrow on the outboard side of the seatback (Figure 1). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > Customer Interest for Seat Latch: > 23-31-00 > Aug > 00 > Seat - Rattle/Chuck in Upright Position > Page 6350 5. Remove bolts attaching the outboard latch to the seat cushion and seat back frame. 6. Disconnect the cable to the outboard latch. 7. Connect the cable to the new outboard latch (see Parts Required section). 8. Install the new outboard latch onto the seat cushion and seat back frame. Tighten the bolt located in the round hole first, than the bolts located in the slotted holes (Figure 2). Tighten the bolts to 27 N.m (19 ft.lbs.). NOTE: THE SEAT MUST BE IN THE FORWARD TUMBLED POSITION PRIOR TO TIGHTENING THE NEW OUTBOARD LATCH. FAILURE TO TIGHTEN THE LATCH IN THIS POSITION COULD RESULT IN LOOSENESS BETWEEN THE LATCH AND THE SEAT CUSHION FRAME CAUSING A CHUCK/RATTLE IN THE OUTBOARD LATCH. 9. Engage the seat cover hook-and-arrow on the outboard side of the seatback. 10. Install the outboard latch cover and secure it with the three screws. 11. Install the outboard latch release handle and secure it with the screw. 12. Remove and install the second row outboard latch on the other seat using the procedure described in Steps 1 through 11. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Latch: > 23-31-00 > Aug > 00 > Seat - Rattle/Chuck in Upright Position Seat Latch: All Technical Service Bulletins Seat - Rattle/Chuck in Upright Position NUMBER: 23-31-00 GROUP: Body DATE: August 18, 2000 SUBJECT: Rattle/Chuck In The Second Row Seat When Seat Is In Upright Position OVERVIEW: This bulletin involves installing revised outboard seat back latches on both right side and left side second row seats. MODELS: 1998 - 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 40/20/40 SECOND ROW SPLIT BENCH SEAT (SALES CODE CFM). SYMPTOM/CONDITION: The 40/20/40 second row split bench seat back may chuck or rattle while in the upright and locked position when going over bumps. DIAGNOSIS: With the second row seat latched in the upright position, firmly grab the seat back on the upper outboard corner of either 40% portion of the second row seat and push in a fore-aft motion. If the seat latch rattles when you push the seat back fore and aft, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: This repair is Compatible with Daimler Chrysler's Mobile Service program And does Not Require Hoists or Other Full Service facility special Equipment. 1. Tumble the seat forward. 2. Remove the screw that secures the outboard latch release handle and remove the handle. 3. Remove the three screws that secure the outboard latch cover and remove the latch cover. 4 Disengage the seat cover hook-and-arrow on the outboard side of the seatback (Figure 1). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Latch: > 23-31-00 > Aug > 00 > Seat - Rattle/Chuck in Upright Position > Page 6356 5. Remove bolts attaching the outboard latch to the seat cushion and seat back frame. 6. Disconnect the cable to the outboard latch. 7. Connect the cable to the new outboard latch (see Parts Required section). 8. Install the new outboard latch onto the seat cushion and seat back frame. Tighten the bolt located in the round hole first, than the bolts located in the slotted holes (Figure 2). Tighten the bolts to 27 N.m (19 ft.lbs.). NOTE: THE SEAT MUST BE IN THE FORWARD TUMBLED POSITION PRIOR TO TIGHTENING THE NEW OUTBOARD LATCH. FAILURE TO TIGHTEN THE LATCH IN THIS POSITION COULD RESULT IN LOOSENESS BETWEEN THE LATCH AND THE SEAT CUSHION FRAME CAUSING A CHUCK/RATTLE IN THE OUTBOARD LATCH. 9. Engage the seat cover hook-and-arrow on the outboard side of the seatback. 10. Install the outboard latch cover and secure it with the three screws. 11. Install the outboard latch release handle and secure it with the screw. 12. Remove and install the second row outboard latch on the other seat using the procedure described in Steps 1 through 11. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Specifications Power Door Lock Switch: Specifications Power Lock Switch Mounting Screws 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Specifications > Page 6361 Driver Power Window/Door Lock Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Specifications > Page 6362 Power Door Lock Switch: Description and Operation SYSTEM OPERATION The power locks can be controlled by a two-way switch integral to the power window and lock switch unit on the driver side front door trim panel, or a two-way single gang switch on the passenger side front door trim panel. The power lock switch controls the battery feeds to the lock and unlock sense inputs of the high-line Central Timer Module (CTM). The CTM then relays the correct battery and ground feeds to the power lock motors. A Light-Emitting Diode (LED) in the paddle of each switch is illuminated whenever the ignition switch is in the On position. The driver side power window and lock switch unit cannot be repaired and, if faulty or damaged, the entire switch unit must be replaced. The passenger side power lock switch cannot be repaired and, if faulty or damaged, the switch must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Specifications > Page 6363 Power Door Lock Switch: Testing and Inspection If the problem being diagnosed involves only the power lock switch illumination LEDs, check the fused ignition switch output (run) and ground circuits at the power lock switch connector. 1. Check the 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. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Unplug the wire harness connector from the power lock switch. 4. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the body half of the power lock switch wire harness connector. If OK, go to Step 5. If not OK, repair the open circuit to the junction block as required. Power Lock Switch Continuity - Driver Side Power Lock Switch Continuity - Passenger Side 5. Test the power lock switch continuity See the Power Lock Switch Continuity charts to determine if the continuity is correct in the Off, Lock and Unlock switch positions. If OK, repair the door lock switch output (lock Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Specifications > Page 6364 and/or unlock) circuit(s) from the body half of the power lock switch wire harness connector to the Central Timer Module (CTM) as required. If not OK, replace the faulty switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Specifications > Page 6365 Power Door Lock Switch: Service and Repair REMOVAL Driver Side Front Door 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the driver side front door. 3. From the back side of the trim panel, remove the screws that secure the power window and lock switch unit to the switch bezel in the door trim panel opening. 4. Remove the power window and lock switch and the switch bezel from the door trim panel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Passenger Side Front Door 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the passenger side front door. 3. With a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power window switch receptacle on the back of the door trim panel switch bezel and pull the switch out of the receptacle. 4. Reverse the removal procedures to install. Be certain that both of the switch snap retainers in the receptacle on the back of the door trim panel switch bezel are fully engaged. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Power Mirror Switch Knob Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 6369 Power Mirror Switch: Description and Operation SYSTEM DESCRIPTION Both the right and left power outside mirrors are controlled by a single multi-function switch unit located on and mounted to the upper flag area of the driver side door trim panel. The switch knob is rotated clockwise (right mirror control), or counterclockwise (left mirror control) to select the mirror to be adjusted. The switch knob is then moved in a joystick fashion to control movement of the selected mirror up, down, right, or left. The power mirror switch cannot be repaired and, if faulty or damaged, it must be replaced. The power mirror switch knob is available for service replacement. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 6370 Power Mirror Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Mirror Switch Knob Remove/Install 2. Pull the power mirror switch control knob rearward to remove it from the switch stem. Power Mirror Switch Nut 3. Remove the nut that secures the power mirror switch to the driver side door trim panel. 4. Remove the trim panel from the inside of the driver side front door. 5. Pull the trim panel away from the inner door panel far enough to access the power mirror switch wire harness connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 6371 Door Trim Panel Wire Harness Connectors 6. Unplug the power mirror switch wire harness connector. 7. Remove the power mirror switch from the back of the door trim panel. 8. Reverse the removal procedures to install. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications Power Seat Switch: Specifications Power Seat Switch Mounting Screws 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications > Page 6375 Power Seat Switch: Locations Power Seat Switch Remove/Install - Typical The switch is located on the lower outboard side of the seat cushion on the seat cushion side shield. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications > Page 6376 Power Seat Switch: Description and Operation SYSTEM OPERATION The power seat can be adjusted in six different ways using the power seat switch. The switch is located on the lower outboard side of the seat cushion on the seat cushion side shield. Refer to the owner's manual for more information on the power seat switch functions and the seat adjusting procedures. The individual switches in the power seat switch unit cannot be repaired. If one switch is damaged or faulty, the entire power seat switch unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications > Page 6377 Power Seat Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Power Seat Switch Continuity 3. Use an ohmmeter to test the continuity of the power seat switches in each position. See the Power Seat Switch Continuity chart. If OK, see Power Seat Adjuster and Motors in the Diagnosis and Testing. If not OK, replace the faulty power seat switch unit. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications > Page 6378 Power Seat Switch: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the driver side front seat. 3. Pull the recliner lever off of the recliner mechanism release shaft. 4. Remove the three screws that secure the driver side seat cushion side shield to the outboard seat cushion frame. 5. Pull the driver side seat cushion side shield away from the seat cushion frame far enough to access the power seat switch module wire harness connector. 6. Unplug the wire harness connector from the power seat switch module. 7. Remove the seat cushion side shield and power seat switch module from the seat as a unit. Power Seat Switch Remove/Install - Typical 8. Remove the two screws that secure the power seat switch to the inside of the seat cushion side shield. 9. Remove the power seat switch from the seat cushion side shield. 10. Reverse the removal procedures to install. Tighten the switch mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Opening Front Door Weatherstrip: Service and Repair Front Door Opening REMOVAL 1. Remove A-pillar trim. 2. Remove lower cowl trim. 3. Remove door sill trim. 4. Loosen upper and lower B-pillar trim to access weatherstrip. 5. Pull weatherstrip from pinch flange around door opening. 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. Ensure the clips attaching the sill trim to the door sill are fully seated. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Opening > Page 6389 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Opening > Page 6390 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Opening > Page 6391 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Opening > Page 6392 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Glass Run Weatherstrip 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Glass Run Weatherstrip > Page 6397 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Glass Run Weatherstrip > Page 6398 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Glass Run Weatherstrip > Page 6399 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Hood Seal > Page 6404 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal > Page 6409 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal > Page 6410 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal > Page 6411 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal > Page 6412 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6417 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6418 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6419 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Brake Switch (Cruise Control): Locations The switch is mounted on the brake pedal mounting bracket under the instrument panel Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 6427 Brake Switch (Cruise Control): Description and Operation DESCRIPTION The switch is mounted on the brake pedal mounting bracket under the instrument panel. OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The PCM monitors the state of the dual function stop lamp switch. Refer to the Brake for more information on stop lamp switch service and adjustment procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications Cruise Control Servo: Specifications Tighten servo mounting nuts to 8.5 N.m (75 in. lbs.). Servo Mounting Bracket-to-Servo Nuts 8.5 N.m (75 in. lbs.) Servo Mounting Bracket-to-Body Nuts 7-10 N.m (63-94 in. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 6431 Speed Control Servo Location Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 6432 Vehicle Speed Control Servo Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 6433 Cruise Control Servo: Description and Operation DESCRIPTION The servo unit consists of a solenoid valve body, a vacuum servo and the mounting bracket. OPERATION 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. A cable connects the servo with the throttle linkage. The servo unit cannot be repaired and is serviced only as a complete assembly Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 6434 Cruise Control Servo: Testing and Inspection For complete speed control system diagnosis, refer to the appropriate Powertrain Diagnostic Procedures. To test the speed control servo only, refer to the following: The engine must be started and running for the following voltage tests. 1. Start engine. 2. Disconnect 4-way electrical connector at servo. 3. Turn speed control switch to ON position. Fig. 4 Servo Harness Connector 4. Check for battery voltage at pin-3 of wiring harness 4-way connector. This is the 12 volt feed from the stoplamp switch. When the brake pedal is depressed, voltage should not be present at pin-3. If voltage is not present with brake pedal not depressed, check for continuity between servo and stop lamp switch. Also check stop lamp switch adjustment. 5. Connect a small gauge jumper wire between the disconnected servo harness 4-way connector pin-3, and pin-3 on the servo. Check for battery voltage at pins-1, 2 and 4 of the servo. If battery voltage is not at these pins, replace the servo. 6. Turn ignition switch to OFF position. Check for continuity between disconnected servo harness 4-way connector pin and a good ground. There should be continuity If not OK, repair open circuit to ground as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 6435 Cruise Control Servo: Service and Repair REMOVAL 1. Disconnect negative battery cable at battery. 2. Disconnect vacuum hose (line) at servo. 3. Disconnect electrical connector at servo. Servo Cable Clip Remove/Install - Typical 4. Disconnect servo cable at throttle body. Refer to Servo Cable Removal/Installation. 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 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 N.m (75 in. lbs.). 5. Connect vacuum line at servo. 6. Connect electrical connector at servo. 7. Connect servo cable to throttle body. Refer to Servo Cable Removal/Installation. 8. Connect negative battery cable to battery. 9. Before starting engine, operate accelerator pedal to check for any binding. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation Cruise Control Servo Cable: Description and Operation DESCRIPTION The speed control servo cable is connected between the speed control vacuum servo diaphragm and the throttle body control linkage. OPERATION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation > Page 6439 Cruise Control Servo Cable: Service and Repair REMOVAL 1. Disconnect negative battery cable at battery Servo Cable Remove/Install 2. Using finger pressure only, remove speed control cable connector at throttle body bellcrank by pushing connector off the bellcrank pin. DO NOT try to pull connector off perpendicular to the bellcrank pin. Connector will be broken. 3. Squeeze 2 tabs on sides of speed control cable at throttle body mounting bracket (locking plate) and push out of bracket. 4. 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 and Installation. 2. Install cable into throttle body mounting bracket (snaps in). 3. Install speed control cable connector at throttle body bellcrank pin (snaps on). 4. Connect negative battery cable at battery 5. Before starting engine, operate accelerator pedal to check for any binding. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Specifications Cruise Control Switch: Specifications Tighten screws to 1.5 N.m (14 in. lbs.) torque Switch Module Mounting Screws 1.5 N.m (14 in. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6443 Speed Control Switches Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Left Speed Control Switch - White 2 Way Left Speed Control Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Left Speed Control Switch - White 2 Way > Page 6446 Right Speed Control Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6447 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6448 Cruise Control Switch: Description and Operation DESCRIPTION Two separate speed control switch modules are mounted on the steering wheel to the left and right side of the driver's airbag module. The two switch modules are labeled: ON/OFF, SET, RESUME/ACCEL, CANCEL and COAST. 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 individual switch fails, the switch module must be replaced. OPERATION Within the two switch modules, five momentary contact switches, supporting seven different speed control functions are used. The outputs from these switches are filtered into one input. The Powertrain Control Module (PCM) determines which output has been applied through resistive multiplexing. The input circuit voltage is measured by the PCM to determine which switch function has been selected. A speed control indicator lamp, located on the instrument panel cluster is energized by the PCM via the CCD Bus. This occurs when speed control system power has been turned ON, and the engine is running. SPEED CONTROL SWITCHES-PCM INPUT Six different speed control functions, using three momentary contact switches, are monitored through this multiplexed input. The resistance monitored at this input, in combination with the length of time the PCM measures the resistance, determines which switch feature has been selected. The three switches are: On/Off; Set/Coast, Cancel and Resume/Accelerate. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6449 Cruise Control Switch: Testing and Inspection To perform a complete test of the speed control switch circuits, refer to the appropriate Powertrain Diagnostic Procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6450 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 N.m (14 in. lbs.) torque 4. Install airbag module. Refer to Passive Restraint Systems for procedures. 5. Connect negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications Cruise Control Vacuum Reservoir: Specifications Tighten three screws plastic cowl cover to 2.2 N.m (20 in. lbs.) torque. Vacuum Reservoir Mounting Screws 2.2 N.m (20 in. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications > Page 6454 Servo Cable Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications > Page 6455 Cruise Control Vacuum Reservoir: Description and Operation DESCRIPTION The vacuum reservoir is a plastic storage tank connected to an engine vacuum source by vacuum lines. OPERATION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications > Page 6456 Cruise Control Vacuum Reservoir: Service and Repair Vacuum Reservoir Mounting The vacuum reservoir is located under the plastic cowl plenum cover at lower base of windshield. REMOVAL 1. Disconnect and isolate negative battery at cable. 2. Remove both windshield wiper arm/blade assemblies. Refer to Wiper and Washer Systems. Cowl Grille Panel Weather-strip 3. Remove rubber weather-strip at front edge of cowl grill. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications > Page 6457 Cowl Plenum Cover/Grille Panel Remove/Install 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. Vacuum Reservoir Mounting 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 1. Install vacuum reservoir and three mounting screws to plastic cowl cover. Tighten three screws to 2.2 N.m (20 in. lbs.) torque. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications > Page 6458 2. Position cowl plenum cover/grille panel to vehicle. 3. Connect vacuum supply hose to vacuum reservoir. 4. Connect windshield washer supply hose at in-line 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Solenoid > Component Information > Description and Operation Cruise Control Vacuum Solenoid: Description and Operation OPERATION When all of the speed control parameters are met, and the SET button is pressed, the PCM actuates the vent solenoid and "duty-cycles" the vacuum solenoid to open the throttle and bring the vehicle up to target speed. When the vehicle is at target speed, it will actuate the vent solenoid with the vacuum solenoid de-activated to maintain the vehicle at target speed. When the vehicle is above target speed, the PCM will "duty-cycle" the vent solenoid with the vacuum solenoid still de-activated to close the throttle to return to target speed. SPEED CONTROL SOLENOIDS-PCM OUTPUT Speed control operation is regulated by the powertrain control module (PCM). The PCM controls the vacuum to the throttle actuator through the speed control vacuum and vent solenoids. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Brake Switch (Cruise Control): Locations The switch is mounted on the brake pedal mounting bracket under the instrument panel Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 6466 Brake Switch (Cruise Control): Description and Operation DESCRIPTION The switch is mounted on the brake pedal mounting bracket under the instrument panel. OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The PCM monitors the state of the dual function stop lamp switch. Refer to the Brake for more information on stop lamp switch service and adjustment procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications Cruise Control Switch: Specifications Tighten screws to 1.5 N.m (14 in. lbs.) torque Switch Module Mounting Screws 1.5 N.m (14 in. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6470 Speed Control Switches Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Left Speed Control Switch - White 2 Way Left Speed Control Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Left Speed Control Switch - White 2 Way > Page 6473 Right Speed Control Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6474 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6475 Cruise Control Switch: Description and Operation DESCRIPTION Two separate speed control switch modules are mounted on the steering wheel to the left and right side of the driver's airbag module. The two switch modules are labeled: ON/OFF, SET, RESUME/ACCEL, CANCEL and COAST. 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 individual switch fails, the switch module must be replaced. OPERATION Within the two switch modules, five momentary contact switches, supporting seven different speed control functions are used. The outputs from these switches are filtered into one input. The Powertrain Control Module (PCM) determines which output has been applied through resistive multiplexing. The input circuit voltage is measured by the PCM to determine which switch function has been selected. A speed control indicator lamp, located on the instrument panel cluster is energized by the PCM via the CCD Bus. This occurs when speed control system power has been turned ON, and the engine is running. SPEED CONTROL SWITCHES-PCM INPUT Six different speed control functions, using three momentary contact switches, are monitored through this multiplexed input. The resistance monitored at this input, in combination with the length of time the PCM measures the resistance, determines which switch feature has been selected. The three switches are: On/Off; Set/Coast, Cancel and Resume/Accelerate. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6476 Cruise Control Switch: Testing and Inspection To perform a complete test of the speed control switch circuits, refer to the appropriate Powertrain Diagnostic Procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6477 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 N.m (14 in. lbs.) torque 4. Install airbag module. Refer to Passive Restraint Systems for procedures. 5. Connect negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Description and Operation Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation The Vehicle Speed Sensor (VSS) is no longer used for any Dodge Truck. Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for speed control system operation. For the location of the transmission output shaft sensor, please refer to Transmission Speed Sensor/Locations. See: Powertrain Management/Computers and Control Systems/Sensors and Switches - Computers and Control Systems/Vehicle Speed Sensor/Locations For the location of the rear wheel speed sensor, please refer to Brakes and Traction Control/Brakes/Antilock Brake System/Wheel Speed Sensor/Locations. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Description and Operation Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation The Vehicle Speed Sensor (VSS) is no longer used for any Dodge Truck. Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for speed control system operation. For the location of the transmission output shaft sensor, please refer to Transmission Speed Sensor/Locations. See: Powertrain Management/Computers and Control Systems/Sensors and Switches - Computers and Control Systems/Vehicle Speed Sensor/Locations For the location of the rear wheel speed sensor, please refer to Brakes and Traction Control/Brakes/Antilock Brake System/Wheel Speed Sensor/Locations. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Application and ID ABS Light: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Anti-lock Brake = Bulb Number PC194 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation > Rear Wheel Antilock Brakes ABS Light: Description and Operation Rear Wheel Antilock Brakes The amber ABS warning lamp is used to alert the driver of an RWAL problem and identify DTCs stored in the CABs memory. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation > Rear Wheel Antilock Brakes > Page 6490 ABS Light: Description and Operation Four Wheel Antilock Brakes The amber ABS warning lamp is located in the instrument cluster. The lamp illuminates at start-up to perform a self check. The lamp goes out when the self check program determines the system is operating normal. If an ABS component exhibits a fault the CAB will illuminate the lamp and register a trouble code in the microprocessor. The lamp is controlled by the CAB. The CAB controls the lamp sending a message to the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation Audible Warning Device: Description and Operation CHIME SYSTEM The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for seat belt, gauge problems and tell-tale warnings. There are two chime rates, Low; 50 ± 12 chimes per minute for reminders and High; 180 ± 12 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 doors are open or the headlights 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 approximately 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 - Seat belt warning - Check engine lamp illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Anti-lock lamp illuminated (after prove-out if equipped) - Check gauges lamp illuminated - Low fuel warning lamp illuminated - Low washer fluid - Door ajar SYSTEM OPERATION The chime warning system provides an audible warning to the driver under the following conditions: ABS lamp illumination - Airbag indicator lamp illumination - Check gauges lamp illumination - Door is ajar with vehicle in motion - Driver side seat belt is not fastened with the ignition switch in the On position - Head or park lamps are turned on with the ignition switch Off and the driver side front door open - Key is in the ignition switch with the ignition switch Off and the driver side front door open - Low fuel warning lamp illumination - less than about one-eighth tank of fuel remaining - Low washer fluid warning lamp illumination - Transmission oil temperature warning lamp illumination. Refer to the owner's manual in the vehicle glove box for more information on the features, use and operation of the chime warning system. 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/Description and Operation Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Page 6494 Audible Warning Device: Service and Repair Service procedures for the various hard-wired switches used in the chime warning system can be found in the Service and Repair as follows: - Driver door ajar switch - Driver seat belt switch - Headlamp switch - refer to Headlamp Switch/Service and Repair. - Key-in ignition switch of Ignition Systems for the ignition switch service procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Specifications Audible Warning Device Control Module: Specifications CTM Mounting Bracket Screws (2) to Bracket on Outboard Side of Glove Box Opening 20 in.lb Bracket on Outboard Side of Glove Box Opening to Instrument Panel Screws (3) 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Specifications > Page 6498 Central Timer Module Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6501 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6502 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6503 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6504 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6505 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6506 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6507 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6508 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6509 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6510 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6511 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6512 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6513 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6514 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6515 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6516 Audible Warning Device Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6517 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6518 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6519 Audible Warning Device Control Module: Connector Views Central Timer Module C1 Central Timer Module C2 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6520 Audible Warning Device Control Module: Electrical Diagrams Center Timer Module 8w-45-2 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6521 8w-45-3 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6522 8w-45-4 (Except Power Locks) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6523 8w-45-5 (Power Locks) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6524 8w-45-6 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6525 8w-45-7 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6526 8w-45-8 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6527 8w-45-9 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6528 8w-45-10 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6529 8w-45-11 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6530 8w-45-12 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6531 8w-45-13 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6532 8w-45-14 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6533 8w-45-15 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6534 Central Timer Module System Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 6535 Audible Warning Device Control Module: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 6536 Audible Warning Device Control Module: 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 NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB scan tool and the proper Diagnostic Procedures. If the problem being diagnosed involves only the RKE driver unlock feature, be certain that the feature is enabled using a DRB scan tool and the proper Diagnostic Procedures. Also, if the problem being diagnosed involves only the driver side front door, see Relays in the Diagnosis and Testing to test the driver unlock relay before testing the CTM. 1. Check the fuses 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. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the procedures. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the CTM for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. Repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Probe the door lock switch output (lock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 8. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 8. Probe the door lock switch output (unlock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 9. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 9. Disconnect and isolate the battery negative cable. Reinstall the wire harness connectors to the CTM. Connect the battery negative cable. Back-probe the door lock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as either power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the Remote Keyless Entry (RKE) transmitter. If OK, go to Step 10. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 10. Back-probe the door unlock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter twice within five seconds. If OK, see Power Lock Motor in the Diagnosis and Testing. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 11. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run/start) circuit cavity of the 14-way CTM wire harness connector. On the high-line version of the CTM, repeat the check at the fused ignition switch output (run/accessory) circuit cavity of the 18-way CTM wire harness connector. If OK, replace the faulty CTM. If not OK, repair the open circuit from the CTM to the junction block as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 6537 Audible Warning Device Control Module: Service and Repair Before replacing a high-line Central Timer Module (CTM), use a DRB scan tool to determine the current settings for the CTM programmable features. These settings should be duplicated in the replacement CTM using the DRB scan tool, before returning the vehicle to service. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box from the instrument panel. Refer to Glove Box - Removal in the Service and Repair for the procedures. Outboard Glove Box Opening Bracket Remove/Install 3. Remove the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Central Timer Module Remove/Install 4. Remove the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. 5. Remove the bracket on the outboard side of the glove box opening from the instrument panel through the glove box opening. 6. Move the CTM and its mounting bracket into the glove box opening far enough to access and disengage the instrument panel wire harness retainer Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 6538 from the CTM mounting bracket. 7. Disconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) from the CTM connector receptacle(s). 8. Remove the CTM and mounting bracket unit from the instrument panel through the glove box opening. INSTALLATION 1. Position the CTM and mounting bracket unit in the instrument panel glove box opening. 2. Reconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) to the CTM connector receptacle(s). 3. Engage the instrument panel wire harness retainer with the hole in the CTM mounting bracket. 4. Engage the tab on the outboard end of the CTM mounting bracket in the slot in the right instrument panel end bracket. 5. Working through the instrument panel glove box opening, position the outboard glove box opening bracket to the CTM mounting bracket. 6. Install and tighten the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. Tighten the screws to 2.2 Nm (20 in. lbs.). 7. Install and tighten the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 8. Install the glove box onto the instrument panel. Refer to Glove Box - Installation/Service and Repair for the procedures. 9. Reconnect the battery negative cable. NOTE: If a new high-line Central Timer Module is installed, the programmable features must be enabled and/or disabled to the customer's preferred settings. Use a DRB scan tool and the proper Diagnostic Procedures to perform these operations. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Service Precautions Brake Warning Indicator: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Service Precautions > Page 6542 Brake Warning Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Brake Warning ..................................................................................................................................... ............................................................. PC194 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > General Information Brake Warning Indicator: Description and Operation General Information A red warning lamp is used for the service brake portion of the hydraulic system. The lamp is located in the instrument cluster. The red warning light alerts the driver if a pressure differential exists between the front and rear hydraulic systems or the parking brakes are applied. The lamp is turned on momentarily when the ignition switch is turn to the on position. This is a self test to verify the lamp is operational. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > General Information > Page 6545 Brake Warning Indicator: Description and Operation Brake Warning Lamp Description The red brake warning lamp is used to alert the driver of a hydraulic fault or that the parking brake is applied. For the RWAL system, the red brake warning lamp also is used to alerts the driver of a problem with the RWAL system. The brake warning lamp illuminates when a message is sent over the bus to the cluster to illuminate the bulb. A ground for the bulb is provided when: The brakes are applied and the park brake switch is actuated. - A hydraulic fault has occurred and the pressure differential switch is actuated. - A RWAL fault has occurred. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > Page 6546 Brake Warning Indicator: Testing and Inspection HARD-WIRED LAMP DIAGNOSIS This lamp depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedure will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS (SUPPLEMENTAL 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. BRAKE WARNING LAMP The diagnosis found here addresses an inoperative brake warning lamp condition. If the brake warning lamp stays on with the ignition switch in the ON position and the park brake released, or comes on while driving, refer to Rear Wheel Antilock for vehicles equipped with a rear wheel anti-lock brake system, or refer to Antilock Brakes for vehicles equipped with a four wheel anti-lock brake system for further diagnosis. If no brake system problem is found, the following procedure will help locate a faulty park brake switch or circuit. For complete circuit diagrams, refer to Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number 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. Thrn 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. Thrn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector at the park brake switch. With the park brake released, check for continuity between the park brake switch terminal and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, adjust or replace the faulty park brake switch. 4. Remove the instrument cluster. With the wire harness connector still disconnected from the park brake switch, check for continuity between the park brake switch sense circuit cavity of the park brake 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 park brake switch sense circuit as required. 5. Check for continuity between the park brake switch sense circuit cavities of the instrument cluster wire harness connector A and the park brake switch wire harness connector. There should be continuity. If OK, refer to Instrument Cluster Instrument Panel Test/Preliminary Diagnosis for further testing of the brake warning lamp and the instrument cluster circuitry. See: Instrument Cluster / Carrier/Testing and Inspection If not OK, repair the open park brake switch sense circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Locations Cigarette Lighter: Locations Instrument Panel Cigar Lighter And Power Outlet 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6552 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6553 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6554 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6555 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6556 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6557 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6558 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6559 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6560 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6561 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6562 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6563 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6564 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6565 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6566 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6567 Cigarette Lighter: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6568 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6569 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6570 Cigarette Lighter: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6571 Cigarette Lighter: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Cigar Lighter ........................................................................................................................................ .................................................................. 161 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6572 Cigarette Lighter: Description and Operation DESCRIPTION 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. OPERATION 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 in 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6573 Cigarette Lighter: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG 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 receptade. If not OK, repair the open fused ignition switch output (run/accessory) circuit to the junction block fuse as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6574 Cigarette Lighter: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the lower bezel from the instrument panel. Refer to Instrument Panel Lower Bezel Replacement for the procedures. Instrument Panel Cigar Lighter And Power Outlet 3. Pull the cigar lighter knob and element out of the cigar lighter receptacle base, or unsnap the protective cap from the power outlet receptacle base. Cigar Lighter And Power Outlet Remove/Install - Typical 4. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses of the mount that secures the receptacle base to the instrument panel lower bezel. 5. Insert a pair of external snap ring pliers into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 6. 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. 7. Remove the cigar lighter or power outlet mount from the instrument panel lower bezel. INSTALLATION 1. Install the cigar lighter or power outlet mount into the instrument panel lower bezel. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6575 4. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 5. Install the lower bezel onto the instrument panel. Refer to Instrument Panel Lower Bezel Replacement for the procedures. 6. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Specifications Compass: Specifications Tighten the four screws that secure the compass mini-trip computer module to the overhead console housing to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Specifications > Page 6579 Compass/Mini Trip Computer Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Specifications > Page 6580 Compass: Description and Operation DESCRIPTION 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 Chrysler Collision Detection (CCD) data bus network. The CCD 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 traveled 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 compass mini-trip computer module. Data input for all other compass mini-trip computer functions, including VFD dimming level, is received through CCD 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 CCD data bus. 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 may be required to restore proper compass operation. 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. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Specifications > Page 6581 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/100Km since the last reset. Instantaneous Fuel Economy Shows the fuel economy for the last few seconds in MPG or L/100Km. 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 minitrip 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, Trip Odometer, ET) is currently being displayed. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Specifications > Page 6582 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 Chrysler Collision Detection (CCD) 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. 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 CCD data bus. If not OK, repair the open fused ignition switch output (run/start) circuit to the junction block fuse as required. Self-Diagnostic Test 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. 2. Turn the ignition switch to the On position. 3. 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: a. Microprocessor compass circuit test b. Non-volatile memory read/write test c. Microprocessor ROM verification test d. CCD communications test. 4. Following completion of these tests, the compass mini-trip computer will return to normal operation or display one of two messages: "FAIL" or "CCD." Respond to these test results as follows: e. 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. f. If the "FAIL" message is displayed, the compass mini-trip computer module is faulty and must be replaced. g. If the "CCD" message is displayed, the use of a DRB scan tool and the proper Diagnostic Procedures are required for further diagnosis. h. 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. 5. If all tests are passed, or if the ignition switch is turned to the Off position, the compass mini-trip computer module will automatically return to normal operation. NOTE: 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Specifications > Page 6583 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. To set the compass variance: Variance Settings 1. Using the Variance Settings map, find your geographic location and note the zone number. 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Calibration Service Compass: Service and Repair Compass Calibration Service 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Calibration Service > Page 6586 Compass: Service and Repair Compass Demagnetizing Service 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. 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. 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, arid 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Calibration Service > Page 6587 Compass: Service and Repair Compass Minitrip Computer Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console from the headliner. Refer to Overhead Console/Service and Repair 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. 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/Service and Repair 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming Disconnect and isolate the battery negative cable. If the airbag module has not been deployed, wait two minutes for the system capacitor to discharge before further service. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 6593 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming 16-Way Data Link Connector - Typical 1. Make sure no one is in the vehicle. 2. Connect the negative battery terminal. 3. Connect the DRB scan tool to the 16-way data link wire harness connector. The connector is located on the driver side lower edge of the instrument panel, outboard of the steering column. 4. Turn the ignition switch to the ON position. Exit the vehicle with the DRB. Use the latest version of the proper DRB cartridge. 5. Erase the stored DTC data. If any problems remain, the stored DTC data will not erase. 6. With the ignition switch still in the ON position, make sure nobody is in the vehicle. 7. From outside of the vehicle (away from the airbag modules in case of an accidental deployment) turn the ignition switch to the OFF position for about 10 seconds, and then back to the ON position. Observe the airbag indicator lamp in the instrument cluster. It should light for six to 8 seconds, and then go out. This indicates that the airbag system is functioning normally. NOTE: If the airbag indicator lamp fails to light, or lights and stays on, there is an airbag system malfunction. Refer to the proper Diagnostic Procedures to diagnose the problem. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams Multi-Function Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Service Precautions Door/Trunk Ajar Indicator/Lamp: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Service Precautions > Page 6600 Door/Trunk Ajar Indicator/Lamp: Testing and Inspection HARD-WIRED LAMP DIAGNOSIS This lamp depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedure will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS (SUPPLEMENTAL 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. LIFTGATE AJAR LAMP The diagnosis found here addresses an inoperative liftgate ajar lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or liftgate ajar switch and not with a damaged or improperly adjusted liftgate latch or latch striker. Inspect the liftgate for proper closing and latch adjustment before you proceed with lamp diagnosis. Refer to Liftgate Latch Service and Repair for more information. For complete circuit diagrams, refer to Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number 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 the wire harness connector from the liftgate ajar switch. Check for continuity between the ground circuit cavity of the liftgate ajar 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. Install a jumper wire between the ground circuit and the liftgate ajar switch sense circuit cavities of the liftgate ajar switch wire harness connector. Turn the ignition switch to the ON position. The liftgate ajar lamp should light. Remove the jumper wire and the lamp should go off. If OK, replace the faulty liftgate latch. If not OK, go to Step 5. 5. Disconnect and isolate the battery negative cable. Remove the instrument cluster. The liftgate ajar switch wire harness connector is still disconnected. Check for continuity between the liftgate ajar switch sense circuit cavity of the instrument cluster wire harness connector B and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted liftgate ajar switch sense circuit as required. 6. Check for continuity between the liftgate ajar switch sense circuit cavities of the instrument cluster wire harness connector B and the liftgate ajar switch wire harness connector. There should be continuity. If OK, refer to Instrument Cluster Instrument Panel Test/Self-Diagnostic Test for further testing of the liftgate ajar lamp and the instrument cluster circuitry. See: Instrument Cluster / Carrier/Testing and Inspection If not OK, repair the open liftgate ajar switch sense circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6605 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6606 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6607 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6608 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6609 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6610 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6611 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6612 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6613 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6614 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6615 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6616 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6617 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6618 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6619 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6620 Door Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6621 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6622 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6623 Compass/Mini-Trip Computer Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 6624 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 6625 Door Switch: Description and Operation SYSTEM DESCRIPTION The driver door ajar switch is integral to the driver side front door latch. The switch closes a path to ground for the Central Timer Module (CTM) when the driver door is opened, and opens the ground path when the driver door is closed. The driver door ajar switch cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 6626 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Rotate the headlamp switch knob counterclockwise to ensure that the dome lamps are not switched off. Open the driver door and note whether the interior lamps light. They should light. If OK, see Key-In Ignition Switch and/or Headlamp Switch in the Diagnosis and Testing. If not OK, go to Step 2. 2. Disconnect and isolate the battery negative cable. Unplug the driver door latch wire harness connector. Check for continuity between the ground circuit cavity in the body half of the driver door latch wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the circuit to ground as required. 3. Check for continuity between the driver door ajar switch ground circuit terminal and the driver door ajar switch sense circuit terminal of the driver door latch wire harness connector. There should be continuity with the driver door open, and no continuity with the driver door closed. If OK, go to Step 4. If not OK, replace the faulty latch. 4. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the procedures. Unplug the 14-way CTM wire harness connector. Check for continuity between the driver door ajar switch sense circuit cavity of the 14-way CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5 If not OK, repair the short circuit as required. 5. Check for continuity between the driver door ajar switch sense circuit cavities of the 14-way CTM wire harness connector and the driver door latch wire harness connector. There should be continuity. If OK, see Key-In Ignition Switch and/or Headlamp Switch in the Diagnosis and Testing. If not OK, repair the open circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Service Precautions Four-Wheel Drive (4WD) Indicator Lamp: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Service Precautions > Page 6630 Four-Wheel Drive (4WD) Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Four Wheel Drive Lamp ....................................................................................................................... ................................................................. 161 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Testing and Inspection > Four-Wheel Drive Indicator Lamp - Full Time Four-Wheel Drive (4WD) Indicator Lamp: Testing and Inspection Four-Wheel Drive Indicator Lamp - Full Time HARD-WIRED LAMP DIAGNOSIS This lamp depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedure will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS (SUPPLEMENTAL 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. FOUR-WHEEL DRIVE INDICATOR LAMP - FULL TIME The diagnosis found here addresses an inoperative four-wheel drive indicator lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or switch and not with a damaged or inoperative transfer case or transfer case linkage. Refer to Transmission and Drivetrain/Transfer Case/NV242 Diagnosis for more information. If no transfer case problem is found, the following procedure will help locate a short or open in the indicator lamp circuit. For complete circuit diagrams, refer to Complete Body and Chassis Diagrams, See: Diagrams/Electrical Diagrams/Diagrams By Group Number 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. Disconnect the transfer case switch wire harness connector. Check for continuity between the ground circuit cavity of the transfer case 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. Connect the battery negative cable. Turn the ignition switch to the ON position. Install a jumper wire between the full time four wheel drive indicator lamp driver circuit cavity of the transfer case switch wire harness connector and a good ground. The full time four-wheel drive indicator lamp should light. If OK, replace the faulty transfer case switch. 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 cluster. With the transfer case switch wire harness connector still disconnected, check for continuity between the full time four wheel drive indicator lamp driver circuit cavity of the instrument cluster wire harness connector A and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted full time four wheel drive indicator lamp driver circuit as required. 6. Check for continuity between the full time four wheel drive indicator lamp driver circuit cavities of the instrument cluster wire harness connector A and the transfer case switch wire harness connector. There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open full time four wheel drive indicator lamp driver circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Testing and Inspection > Four-Wheel Drive Indicator Lamp - Full Time > Page 6633 Four-Wheel Drive (4WD) Indicator Lamp: Testing and Inspection Four-Wheel Drive Indicator Lamp - Part Time HARD-WIRED LAMP DIAGNOSIS This lamp depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedure will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS (SUPPLEMENTAL 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. FOUR-WHEEL DRIVE INDICATOR LAMP - PART TIME The diagnosis found here addresses an inoperative four-wheel drive indicator lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or switch and not with a damaged or inoperative transfer case or transfer case linkage. Refer to Transmission and Drivetrain/Transfer Case/NV231 Diagnosis or NV242 Diagnosis for more information. If no transfer case problem is found, the following procedure will help locate a short or open in the indicator lamp circuit. For complete circuit diagrams, refer to Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number 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. Disconnect the transfer case switch wire harness connector. Check for continuity between the ground circuit cavity of the transfer case 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. Connect the battery negative cable. Turn the ignition switch to the ON position. Install a jumper wire between the part time four wheel drive indicator lamp driver circuit cavity of the transfer case switch wire harness connector and a good ground. The part time four-wheel drive indicator lamp should light. If OK, replace the faulty transfer case switch. If not OK, go to Step 5. 5. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector at the Controller Anti-Lock Brake (CAB). Remove the instrument cluster. With the transfer case switch wire harness connector still disconnected, check for continuity between the part time four wheel drive indicator lamp driver circuit cavity of the instrument cluster wire harness connector B and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted part time four wheel drive indicator lamp driver circuit as required. 6. Check for continuity between the part time four wheel drive indicator lamp driver circuit cavities of the instrument cluster wire harness connector B and the transfer case switch wire harness connector. There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open part time four wheel drive indicator lamp driver circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Component Locations Fuel Gauge Sender: Component Locations 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Component Locations > Page 6638 Fuel Fill/Vent Tube Assembly, Rollover Valve, Fuel Pump Module, Fuel Tank, Fuel Filter/Fuel Pressure Regulator Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6639 Fuel Pump Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6640 Fuel Gauge Sender: Description and Operation Fuel Pump Module/Fuel Tank (Top View) Fuel Pump Module Components (Typical Pump Module Shown) FUEL PUMP MODULE The fuel pump module on all models/all engines is installed in the top of the fuel tank. The fuel pump module contains the following components. A combination fuel filter/fuel pressure regulator Electric fuel pump - Fuel pump reservoir - A separate in-tank fuel filter (at bottom of module) - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection at filter/regulator - A metal lock-ring to retain pump module to fuel tank - A gasket between tank flange and module The fuel gauge sending unit (fuel level sensor), and pick-up filter (at bottom of module) may be serviced separately. If the electrical fuel pump requires service, the entire fuel pump module must be replaced. The fuel filter/fuel pressure regulator may be serviced separately. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. FUEL GAUGE SENDING UNIT 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). The resistor track is used to send electrical signals to the Powertrain Control Module (PCM) for fuel gauge operation and for OBDII emission requirements. For fuel gauge operation: As fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge to read full. As fuel level decreases, the float and arm move down. This increases the sending unit resistance causing the fuel gauge to read empty. After this fuel level signal is sent to the PCM, the PCM will transmit the data across the CCD bus circuits to the instrument panel. Here it is translated into the appropriate fuel gauge level reading. For OBD II emission monitor requirements: A voltage signal is sent from the resistor track on the sending unit to the PCM to indicate fuel level. The purpose of this feature is to prevent the OBDII system from recording/setting false misfire and fuel system monitor 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6641 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6642 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 ohms. With float in down position, resistance should be 220 ohms ± 6 ohms. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Gauge Sending Unit Replacement Fuel Gauge Sender: Service and Repair Fuel Gauge Sending Unit Replacement 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. REMOVAL 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/installation. 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. Fuel Gauge Sending Unit Lock Tab/Tracks 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 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. Refer to Fuel Pump Module Removal/Installation. 6. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Gauge Sending Unit Replacement > Page 6645 Fuel Gauge Sender: Service and Repair Fuel Pump Module Replacement REMOVAL WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING FUEL PUMP MODULE, FUEL SYSTEM PRESSURE MUST BE RELEASED. The fuel pump module is located in top of fuel tank. 1. Drain fuel tank and remove tank. Refer to Fuel Tank Removal/lnstallation. 2. Thoroughly wash and clean area around pump module to prevent contaminants from entering tank. Fuel Pump Module And Locking 3. Part of Fuel Tank Removal Procedure: Disconnect EVAP line at pump module; disconnect wiring harness connector at pump module; disconnect fuel line from fuel filter fitting. 4. Rotate fuel filter until its fitting is pointed towards center of pump module. 5. A metal lockring is used to secure fuel pump module to fuel tank. Six metal fingers are molded into the plastic fuel tank. The fingers are used to retain lockring to fuel tank. A rubber gasket is used as a seal between module and fuel tank. 6. Before removing lockring, apply a small amount of engine oil to 6 fingers where fingers meet lockring (to act as a lubricant). 7. Remove (rotate) lockring counterclockwise using a brass or bronze drift punch and a hammer. This must be done while slightly prying back on lock tab. 8. Remove lockring and pump module from fuel tank. INSTALLATION CAUTION: Whenever fuel pump module is serviced, the module gasket must be replaced. 1. Using a new gasket, position fuel pump module into opening in fuel tank. Be sure rubber gasket remains in place. Rotate pump module assembly until module is positioned as shown in. This step must be followed to prevent float/float rod from contacting sides of fuel tank. 2. Before installing lockring, apply a small amount of engine oil to 6 fingers where fingers meet lockring (to act as a lubricant). 3. Position lockring over top of fuel pump module. Tighten finger tight. 4. Install (rotate) lockring clockwise using a brass or bronze drift punch and a hammer. Continue rotating lockring until 6 fingers drop into 6 finger locks and lock tab falls into lockring notch. 5. Install fuel tank. Refer to Fuel Tank Installation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming Disconnect and isolate the battery negative cable. If the airbag module has not been deployed, wait two minutes for the system capacitor to discharge before further service. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 6651 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming 16-Way Data Link Connector - Typical 1. Make sure no one is in the vehicle. 2. Connect the negative battery terminal. 3. Connect the DRB scan tool to the 16-way data link wire harness connector. The connector is located on the driver side lower edge of the instrument panel, outboard of the steering column. 4. Turn the ignition switch to the ON position. Exit the vehicle with the DRB. Use the latest version of the proper DRB cartridge. 5. Erase the stored DTC data. If any problems remain, the stored DTC data will not erase. 6. With the ignition switch still in the ON position, make sure nobody is in the vehicle. 7. From outside of the vehicle (away from the airbag modules in case of an accidental deployment) turn the ignition switch to the OFF position for about 10 seconds, and then back to the ON position. Observe the airbag indicator lamp in the instrument cluster. It should light for six to 8 seconds, and then go out. This indicates that the airbag system is functioning normally. NOTE: If the airbag indicator lamp fails to light, or lights and stays on, there is an airbag system malfunction. Refer to the proper Diagnostic Procedures to diagnose the problem. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Map Lamp > Component Information > Specifications Map Lamp: Specifications Tighten the two screws that secure the reading and courtesy lamp housing to the overhead console housing to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Map Lamp > Component Information > Specifications > Page 6656 Map Lamp: Description and Operation DESCRIPTION The overhead console in this vehicle is equipped with two individual reading and courtesy lamps. The lamp lenses are the only visible components of these lamps. The reading and courtesy lamp lenses are mounted in the overhead console housing between the compass mini-trip computer display and the sunglasses storage bin. Each lamp has its own switch, bulb, and lens; but both lamps share a common lamp housing within the overhead console. The overhead console reading and courtesy lamps operate on battery current that is provided at all times, regardless of the ignition switch position. The ground feed for the lamps is switched through the integral reading and courtesy lamp switches or through the door jamb switches. Each lamp is designed and aimed to provide illumination that will be directed only to that side of the vehicle on which the lamp is located. The reading and courtesy lamp lenses, bulbs and the lamp housing are available for service replacement. The reading and courtesy lamp switches, bulb holders and wiring are only available as part of the overhead console wire harness. If either of the lamp switches or bulb holders is faulty or damaged, the entire overhead console wire harness assembly must be replaced. For service of the reading and courtesy lamp bulbs, refer to Overhead Console Reading Lamp Bulbs/Service and Repair of Lamps. For diagnosis of the reading and courtesy lamps, refer to Lamp Diagnosis in the Diagnosis and Testing of Lamps. OPERATION All reading and courtesy lamps located in the overhead console are activated by the door jamb switches. When all of the doors are closed, these lamps can be individually activated by depressing the corresponding lens. When any door is open, depressing the lamp lenses to activate the lamp switches will not turn the lamps off, See the owner's manual in the vehicle glove box for more information on the use and operation of the overhead console reading and courtesy lamps. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Map Lamp > Component Information > Service and Repair > Overhead Console Reading and Courtesy Lamp Housing Replacement Map Lamp: Service and Repair Overhead Console Reading and Courtesy Lamp Housing Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the compass mini-trip computer module from the overhead console housing. Refer to Compass Mini-Trip Computer/Service and Repair for the procedures. Overhead Console Reading And Courtesy Lamp Housing Remove/Install 3. Remove the two screws that secure the reading and courtesy lamp housing to the overhead console housing. 4. Pull the reading and courtesy lamp housing away from the overhead console housing far enough to turn it over for access to the lamp bulbs. 5. Remove both reading and courtesy lamp bulbs from their bulb holders by pulling them straight out from the holders. 6. Remove both switches from their mounting slots by sliding them towards their respective outboard ends of the reading and courtesy lamp housing. 7. Remove the four bulb holders from their mounting holes in the reading and courtesy lamp housing by depressing the latch on each side of each holder and pushing the bulb side of the holder out through the wire side of the mounting hole. 8. Remove the reading and courtesy lamp housing from the overhead console housing. INSTALLATION 1. Install each of the four bulb holders into their mounting holes in the reading and courtesy lamp housing by inserting the bulb side of the holder into the wire side of the mounting hole and pushing it through the mounting hole until both latches are engaged with the lamp housing. 2. Install both switches into their mounting slots by sliding them inboard from their respective ends of the reading and courtesy lamp housing until they snap into place. 3. Install both reading and courtesy lamp bulbs into their bulb holders by pushing them straight into the holders. 4. Position the reading and courtesy lamp housing onto the overhead console housing. Be certain that the sunglasses storage bin damper spring is engaged in the slot on the rear flange of the reading and courtesy lamp housing. 5. Install and tighten the two screws that secure the reading and courtesy lamp housing to the overhead console housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 6. Install the compass mini-trip computer module into the overhead console housing. Refer to Compass Mini-Trip Computer/Service and Repair for the procedures. 7. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Map Lamp > Component Information > Service and Repair > Overhead Console Reading and Courtesy Lamp Housing Replacement > Page 6659 Map Lamp: Service and Repair Overhead Console Reading and Courtesy Lamp Lens Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Overhead Console Reading And Courtesy Lamp Lens Remove/Install 2. Insert a long, narrow, flat-bladed tool between the edge of the reading and courtesy lamp lens and the overhead console housing just inboard of the lens pivots. 3. Gently pry downward against the reading and courtesy lamp lens until the pivot of the lens is disengaged from the pivot pin in the lens opening of the overhead console housing. 4. Repeat the procedure to disengage the second lens pivot from its pivot pin. 5. Pull the pivot end (inboard side) of the reading and courtesy lamp lens horizontally inboard far enough to disengage the switch actuator tab on the outboard side of the lens from the overhead console housing. 6. Remove the reading and courtesy lamp lens from the overhead console housing. INSTALLATION 1. Position the switch actuator tab on the outboard side of the reading and courtesy lamp lens into the lens opening of the overhead console housing. The lens actuator tab should be positioned directly over the switch plunger, which is located just outboard of the lens opening. 2. Align the two pivots on the inboard side of the reading and courtesy lamp lens with the two pivot pins on the inboard end of the lens opening in the overhead console housing. 3. Push firmly and evenly upward on the reading and courtesy lamp lens directly over each of the two pivots until they snap into place over the pivot pins in the lens opening of the overhead console housing. 4. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key-In Ignition Switch <--> [Key Reminder Switch] > Component Information > Description and Operation Key-In Ignition Switch: Description and Operation The key-in ignition switch is integral to the ignition switch, which is mounted on the right side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition lock cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition lock cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key-In Ignition Switch <--> [Key Reminder Switch] > Component Information > Description and Operation > Page 6663 Key-In Ignition Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. Remove the steering column shrouds. Unplug the key-in ignition switch wire harness connector from the ignition switch. 2. Check for continuity between the key-in ignition switch sense and ground terminals of the key-in ignition switch. There should be continuity with the key in the ignition lock cylinder, and no continuity with the key removed from the ignition lock cylinder. If OK, go to Step 3. If not OK, replace the faulty ignition switch assembly. 3. Open the driver door. Check for continuity between the ground circuit cavity of the key-in ignition 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 the driver door ajar switch as required. 4. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the procedures. Unplug the 14-way CTM wire harness connector. Close the driver door. Check for continuity between the key-in ignition switch sense circuit cavity of the CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the short circuit as required. 5. Check for continuity between the key-in ignition switch sense circuit cavities of the key-in ignition switch wire harness connector and the 14-way CTM wire harness connector. There should be continuity. If OK, test the CTM as described. If not OK, repair the open circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Application and ID Low Fuel Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Low Fuel Lamp .................................................................................................................................... ............................................................. PC194 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Maintenance Required Lamp .............................................................................................................. .............................................................. PC194 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Application and ID Malfunction Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Check Engine Light ............................................................................................................................. .............................................................. PC194 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 6676 Oil Change Reminder Lamp: Service and Repair This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Component Locations Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Component Locations > Page 6681 Oil Pressure Sending Unit/Switch, Camshaft Position Sensor Connector Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 6682 Oil Pressure Sensor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Engine Oil Pressure Lamp ................................................................................................................... .............................................................. PC194 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation OVERDRIVE LAMP-PCM OUTPUT This circuit controls a signal for the operation of the push-button overdrive lamp switch. When the lamp is illuminated, the overdrive is disengaged. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Specifications Audible Warning Device Control Module: Specifications CTM Mounting Bracket Screws (2) to Bracket on Outboard Side of Glove Box Opening 20 in.lb Bracket on Outboard Side of Glove Box Opening to Instrument Panel Screws (3) 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Specifications > Page 6693 Central Timer Module Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6696 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6697 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6698 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6699 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6700 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6701 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6702 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6703 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6704 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6705 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6706 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6707 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6708 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6709 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6710 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6711 Audible Warning Device Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6712 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6713 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6714 Audible Warning Device Control Module: Connector Views Central Timer Module C1 Central Timer Module C2 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6715 Audible Warning Device Control Module: Electrical Diagrams Center Timer Module 8w-45-2 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6716 8w-45-3 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6717 8w-45-4 (Except Power Locks) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6718 8w-45-5 (Power Locks) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6719 8w-45-6 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6720 8w-45-7 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6721 8w-45-8 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6722 8w-45-9 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6723 8w-45-10 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6724 8w-45-11 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6725 8w-45-12 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6726 8w-45-13 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6727 8w-45-14 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6728 8w-45-15 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 6729 Central Timer Module System Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 6730 Audible Warning Device Control Module: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 6731 Audible Warning Device Control Module: 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 NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB scan tool and the proper Diagnostic Procedures. If the problem being diagnosed involves only the RKE driver unlock feature, be certain that the feature is enabled using a DRB scan tool and the proper Diagnostic Procedures. Also, if the problem being diagnosed involves only the driver side front door, see Relays in the Diagnosis and Testing to test the driver unlock relay before testing the CTM. 1. Check the fuses 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. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the procedures. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the CTM for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. Repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Probe the door lock switch output (lock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 8. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 8. Probe the door lock switch output (unlock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 9. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 9. Disconnect and isolate the battery negative cable. Reinstall the wire harness connectors to the CTM. Connect the battery negative cable. Back-probe the door lock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as either power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the Remote Keyless Entry (RKE) transmitter. If OK, go to Step 10. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 10. Back-probe the door unlock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter twice within five seconds. If OK, see Power Lock Motor in the Diagnosis and Testing. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 11. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run/start) circuit cavity of the 14-way CTM wire harness connector. On the high-line version of the CTM, repeat the check at the fused ignition switch output (run/accessory) circuit cavity of the 18-way CTM wire harness connector. If OK, replace the faulty CTM. If not OK, repair the open circuit from the CTM to the junction block as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 6732 Audible Warning Device Control Module: Service and Repair Before replacing a high-line Central Timer Module (CTM), use a DRB scan tool to determine the current settings for the CTM programmable features. These settings should be duplicated in the replacement CTM using the DRB scan tool, before returning the vehicle to service. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box from the instrument panel. Refer to Glove Box - Removal in the Service and Repair for the procedures. Outboard Glove Box Opening Bracket Remove/Install 3. Remove the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Central Timer Module Remove/Install 4. Remove the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. 5. Remove the bracket on the outboard side of the glove box opening from the instrument panel through the glove box opening. 6. Move the CTM and its mounting bracket into the glove box opening far enough to access and disengage the instrument panel wire harness retainer Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 6733 from the CTM mounting bracket. 7. Disconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) from the CTM connector receptacle(s). 8. Remove the CTM and mounting bracket unit from the instrument panel through the glove box opening. INSTALLATION 1. Position the CTM and mounting bracket unit in the instrument panel glove box opening. 2. Reconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) to the CTM connector receptacle(s). 3. Engage the instrument panel wire harness retainer with the hole in the CTM mounting bracket. 4. Engage the tab on the outboard end of the CTM mounting bracket in the slot in the right instrument panel end bracket. 5. Working through the instrument panel glove box opening, position the outboard glove box opening bracket to the CTM mounting bracket. 6. Install and tighten the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. Tighten the screws to 2.2 Nm (20 in. lbs.). 7. Install and tighten the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 8. Install the glove box onto the instrument panel. Refer to Glove Box - Installation/Service and Repair for the procedures. 9. Reconnect the battery negative cable. NOTE: If a new high-line Central Timer Module is installed, the programmable features must be enabled and/or disabled to the customer's preferred settings. Use a DRB scan tool and the proper Diagnostic Procedures to perform these operations. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams Multi-Function Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6742 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6743 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6744 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6745 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6746 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6747 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6748 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6749 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6750 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6751 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6752 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6753 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6754 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6755 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6756 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6757 Door Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6758 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6759 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6760 Compass/Mini-Trip Computer Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 6761 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 6762 Door Switch: Description and Operation SYSTEM DESCRIPTION The driver door ajar switch is integral to the driver side front door latch. The switch closes a path to ground for the Central Timer Module (CTM) when the driver door is opened, and opens the ground path when the driver door is closed. The driver door ajar switch cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 6763 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Rotate the headlamp switch knob counterclockwise to ensure that the dome lamps are not switched off. Open the driver door and note whether the interior lamps light. They should light. If OK, see Key-In Ignition Switch and/or Headlamp Switch in the Diagnosis and Testing. If not OK, go to Step 2. 2. Disconnect and isolate the battery negative cable. Unplug the driver door latch wire harness connector. Check for continuity between the ground circuit cavity in the body half of the driver door latch wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the circuit to ground as required. 3. Check for continuity between the driver door ajar switch ground circuit terminal and the driver door ajar switch sense circuit terminal of the driver door latch wire harness connector. There should be continuity with the driver door open, and no continuity with the driver door closed. If OK, go to Step 4. If not OK, replace the faulty latch. 4. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the procedures. Unplug the 14-way CTM wire harness connector. Check for continuity between the driver door ajar switch sense circuit cavity of the 14-way CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5 If not OK, repair the short circuit as required. 5. Check for continuity between the driver door ajar switch sense circuit cavities of the 14-way CTM wire harness connector and the driver door latch wire harness connector. There should be continuity. If OK, see Key-In Ignition Switch and/or Headlamp Switch in the Diagnosis and Testing. If not OK, repair the open circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Component Locations Fuel Gauge Sender: Component Locations 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Component Locations > Page 6768 Fuel Fill/Vent Tube Assembly, Rollover Valve, Fuel Pump Module, Fuel Tank, Fuel Filter/Fuel Pressure Regulator Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6769 Fuel Pump Module Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6770 Fuel Gauge Sender: Description and Operation Fuel Pump Module/Fuel Tank (Top View) Fuel Pump Module Components (Typical Pump Module Shown) FUEL PUMP MODULE The fuel pump module on all models/all engines is installed in the top of the fuel tank. The fuel pump module contains the following components. A combination fuel filter/fuel pressure regulator Electric fuel pump - Fuel pump reservoir - A separate in-tank fuel filter (at bottom of module) - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection at filter/regulator - A metal lock-ring to retain pump module to fuel tank - A gasket between tank flange and module The fuel gauge sending unit (fuel level sensor), and pick-up filter (at bottom of module) may be serviced separately. If the electrical fuel pump requires service, the entire fuel pump module must be replaced. The fuel filter/fuel pressure regulator may be serviced separately. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. FUEL GAUGE SENDING UNIT 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). The resistor track is used to send electrical signals to the Powertrain Control Module (PCM) for fuel gauge operation and for OBDII emission requirements. For fuel gauge operation: As fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge to read full. As fuel level decreases, the float and arm move down. This increases the sending unit resistance causing the fuel gauge to read empty. After this fuel level signal is sent to the PCM, the PCM will transmit the data across the CCD bus circuits to the instrument panel. Here it is translated into the appropriate fuel gauge level reading. For OBD II emission monitor requirements: A voltage signal is sent from the resistor track on the sending unit to the PCM to indicate fuel level. The purpose of this feature is to prevent the OBDII system from recording/setting false misfire and fuel system monitor 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6771 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6772 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 ohms. With float in down position, resistance should be 220 ohms ± 6 ohms. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Gauge Sending Unit Replacement Fuel Gauge Sender: Service and Repair Fuel Gauge Sending Unit Replacement 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. REMOVAL 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/installation. 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. Fuel Gauge Sending Unit Lock Tab/Tracks 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 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. Refer to Fuel Pump Module Removal/Installation. 6. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Gauge Sending Unit Replacement > Page 6775 Fuel Gauge Sender: Service and Repair Fuel Pump Module Replacement REMOVAL WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING FUEL PUMP MODULE, FUEL SYSTEM PRESSURE MUST BE RELEASED. The fuel pump module is located in top of fuel tank. 1. Drain fuel tank and remove tank. Refer to Fuel Tank Removal/lnstallation. 2. Thoroughly wash and clean area around pump module to prevent contaminants from entering tank. Fuel Pump Module And Locking 3. Part of Fuel Tank Removal Procedure: Disconnect EVAP line at pump module; disconnect wiring harness connector at pump module; disconnect fuel line from fuel filter fitting. 4. Rotate fuel filter until its fitting is pointed towards center of pump module. 5. A metal lockring is used to secure fuel pump module to fuel tank. Six metal fingers are molded into the plastic fuel tank. The fingers are used to retain lockring to fuel tank. A rubber gasket is used as a seal between module and fuel tank. 6. Before removing lockring, apply a small amount of engine oil to 6 fingers where fingers meet lockring (to act as a lubricant). 7. Remove (rotate) lockring counterclockwise using a brass or bronze drift punch and a hammer. This must be done while slightly prying back on lock tab. 8. Remove lockring and pump module from fuel tank. INSTALLATION CAUTION: Whenever fuel pump module is serviced, the module gasket must be replaced. 1. Using a new gasket, position fuel pump module into opening in fuel tank. Be sure rubber gasket remains in place. Rotate pump module assembly until module is positioned as shown in. This step must be followed to prevent float/float rod from contacting sides of fuel tank. 2. Before installing lockring, apply a small amount of engine oil to 6 fingers where fingers meet lockring (to act as a lubricant). 3. Position lockring over top of fuel pump module. Tighten finger tight. 4. Install (rotate) lockring clockwise using a brass or bronze drift punch and a hammer. Continue rotating lockring until 6 fingers drop into 6 finger locks and lock tab falls into lockring notch. 5. Install fuel tank. Refer to Fuel Tank Installation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key-In Ignition Switch <--> [Key Reminder Switch] > Component Information > Description and Operation Key-In Ignition Switch: Description and Operation The key-in ignition switch is integral to the ignition switch, which is mounted on the right side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition lock cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition lock cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key-In Ignition Switch <--> [Key Reminder Switch] > Component Information > Description and Operation > Page 6779 Key-In Ignition Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. Remove the steering column shrouds. Unplug the key-in ignition switch wire harness connector from the ignition switch. 2. Check for continuity between the key-in ignition switch sense and ground terminals of the key-in ignition switch. There should be continuity with the key in the ignition lock cylinder, and no continuity with the key removed from the ignition lock cylinder. If OK, go to Step 3. If not OK, replace the faulty ignition switch assembly. 3. Open the driver door. Check for continuity between the ground circuit cavity of the key-in ignition 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 the driver door ajar switch as required. 4. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the procedures. Unplug the 14-way CTM wire harness connector. Close the driver door. Check for continuity between the key-in ignition switch sense circuit cavity of the CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the short circuit as required. 5. Check for continuity between the key-in ignition switch sense circuit cavities of the key-in ignition switch wire harness connector and the 14-way CTM wire harness connector. There should be continuity. If OK, test the CTM as described. If not OK, repair the open circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Service and Repair > Page 6783 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation Tachometer: Description and Operation TACHOMETER-PCM OUTPUT The Powertrain Control Module (PCM) supplies engine rpm values to the instrument cluster tachometer. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. bulb Application Temperature Indicator Lamp ............................................................................................................... .............................................................. PC194 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Specifications Transmission Shift Position Indicator Lamp: Specifications Tighten the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Specifications > Page 6793 Transmission Shift Position Indicator Lamp: Locations Gear Selector Indicator Remove/Install The indicator housing is mounted to the rear of the instrument cluster housing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Specifications > Page 6794 Transmission Shift Position Indicator Lamp: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Specifications > Page 6795 Transmission Shift Position Indicator Lamp: Description and Operation GEAR SELECTOR INDICATOR DESCRIPTION An automatic transmission gear selector indicator is standard factory-installed equipment in this model. The mechanical gear selector indicator gives an indication of the transmission gear that has been selected with the automatic transmission gear selector lever. The indicator housing is mounted to the rear of the instrument cluster housing. The gear selector indicator pointer is easily visible through an opening provided in the front of the instrument cluster mask, and is also lighted by the cluster illumination lamps for visibility at night. This covers only the removal and installation of the gear selector indicator from the instrument cluster. OPERATION The gear selector indicator has a spring-loaded pointer that is mechanically actuated by a cable connected to the gear selector indicator driver lever of the gear selector lever mechanism on the steering column. When the gear selector lever is moved the indicator driver lever moves, which actuates the spring-loaded pointer through the mechanical actuator cable. An adjuster mounted on the steering column housing provides a mechanical means of calibrating the gear selector indicator mechanism. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Specifications > Page 6796 Transmission Shift Position Indicator Lamp: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster from the instrument panel. Refer to Instrument Cluster/Service and Repair for the procedures. Gear Selector Indicator Remove/Install 3. Remove the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing. 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. Refer to Steering Column Opening Cover/Service and Repair for the procedures. Gear Selector Indicator Cable Remove/Install 6. Disengage the loop end of the gear selector indicator cable from the lever on the left side of the steering column. 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. 8. Remove the gear selector indicator mechanism and cable unit from the instrument panel. INSTALLATION 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. 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 Nm (20 in. lbs.). 6. Install the instrument cluster onto the instrument panel. Refer to Instrument Cluster/Service and Repair for the procedures. 7. Check the gear selector indicator for proper calibration. 8. Install the steering column opening cover onto the instrument panel. Refer to Steering Column Opening Cover/Service and Repair for the procedures. 9. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Transmission Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information > Locations Tail, Stop, Turn Signal And Back-Up Lamp Bulbs Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information > Locations > Page 6805 Backup Light Bulb: Service and Repair REMOVAL 1. Release liftgate latch and open liftgate. 2. Remove screws attaching tail, stop, turn signal and back-up lamp to liftgate opening. 3. Separate inner end of lamp from quarter panel. 4. Disengage hook holding outer end of lamp to quarter panel opening. 5. Separate lamp from quarter panel. Tail, Stop, Turn Signal And Back-Up Lamp Bulbs 6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp. Pull Bulb From Socket 8. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Locations Tail, Stop, Turn Signal And Back-Up Lamp Bulbs Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Locations > Page 6810 Brake Light Bulb: Service and Repair REMOVAL 1. Release liftgate latch and open liftgate. 2. Remove screws attaching tail, stop, turn signal and back-up lamp to liftgate opening. 3. Separate inner end of lamp from quarter panel. 4. Disengage hook holding outer end of lamp to quarter panel opening. 5. Separate lamp from quarter panel. Tail, Stop, Turn Signal And Back-Up Lamp Bulbs 6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp. Pull Bulb From Socket 8. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Lighting - Stop Lamp Switch Service Revisions Brake Light Switch: Technical Service Bulletins Lighting - Stop Lamp Switch Service Revisions NUMBER: 26-05-99A GROUP: Miscellaneous DATE: May, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1999 Durango Service Manual - Publication Number 81-370-9116 DESCRIPTION OF CHANGES Revisions to the Stop Lamp Switch Service Procedures Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Lighting - Stop Lamp Switch Service Revisions > Page 6815 5-2 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Lighting - Stop Lamp Switch Service Revisions > Page 6816 5-12 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 6817 Brake Lamp Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 6818 Brake Lamp Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > With Antilock Brakes Brake Light Switch: Description and Operation With Antilock Brakes The primary function of the switch is to turn on the stop 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. When the brake light switch is activated, the Powertrain Control Module (PCM) receives an input indicating that the brakes are being applied. After receiving this input, the PCM maintains idle speed to a scheduled rpm through control of the Idle Air Control (IAC) motor. The brake switch input is also used to disable vent and vacuum solenoid output signals to the speed control servo. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > With Antilock Brakes > Page 6821 Brake Light Switch: Description and Operation With Standard Brakes The content of this article reflects the changes called out by TSB 26-05-99. The stop lamp switch is mounted on a bracket on 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 6822 Brake Light Switch: Testing and Inspection The stop lamp switch has a 12 volt feed circuit from the fuse block. Verify fuse is OK, then check the feed from the fuse block to the switch. If the switch has 12 volts depress the brake pedal and check for voltage to the stop lamp circuit. If no voltage is present the switch must be replaced. If the switch does not have 12 volts from the fuse block check for continuity between the fuse block the switch and repair as necessary. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 6823 Brake Light Switch: Service and Repair The content of this article reflects the changes called out by TSB 26-05-99. REMOVAL Stop Lamp Switch & Bracket 1. Disconnect switch harness. 2. Press and hold brake pedal in applied position. 3. Rotate switch counterclockwise about 30° 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. Install switch. Align tab on 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > Liftgate/Cargo Lamp Cargo Lamp: Service and Repair Liftgate/Cargo Lamp 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > Liftgate/Cargo Lamp > Page 6828 Cargo Lamp: Service and Repair Liftgate/Cargo Lamp Bulb REMOVAL 1. Remove liftgate/cargo lamp from liftgate. 2. Using a small flatblade, 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Center High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair Center Mounted Brake Lamp Bulb: Service and Repair REMOVAL 1. Remove CHMSL from liftgate. 2. Turn bulb socket 1/4 turn counterclockwise. 3. Separate socket from lamp. 4. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Locations Glove Box Lamp And Switch Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Locations > Page 6837 Glove Box Lamp: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Locations > Page 6838 Glove Box Lamp: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. REMOVAL 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Locations Glove Box Lamp And Switch Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Locations > Page 6842 Glove Box Lamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Locations > Page 6843 Glove Box Lamp Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. REMOVAL 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations Daytime Running Lamp Module The Daytime Running Lamp Module is located on the left inner fender Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 6848 Daytime Running Lamp Control Unit: Description and Operation GENERAL INFORMATION The headlamps on vehicles sold in Canada, will go on when the ignition is turned ON. The module must also receive a signal from the engine controller. This provides a constant Lights On condition while the vehicle is rolling. The lamps illuminate at less than 50% of normal intensity. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 6849 Daytime Running Lamp Control Unit: Service and Repair The Daytime Running Lamp Module is located on the left inner fender. REMOVAL Daytime Running Lamp Module 1. Remove the bolt attaching the module to the inner fender. 2. Disconnect the electrical connector. INSTALLATION 1. Connect the electrical connector. 2. Insert the tab on the DRLM into the slot on the left inner fender. 3. Install the bolt attaching the module to the left inner fender. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams Multi-Function Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Locations Lamp Lens Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Locations > Page 6857 Dome Lamp Bulb: Service and Repair 2nd Seat Dome/Reading Lamp Bulb REMOVAL Lamp Lens 1. Using a small flat blade, pry the center rearward edge of the dome/reading lamp lens downward from lamp. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6862 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6863 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6864 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6865 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6866 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6867 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6868 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6869 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6870 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6871 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6872 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6873 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6874 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6875 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6876 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6877 Door Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6878 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6879 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6880 Compass/Mini-Trip Computer Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 6881 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 6882 Door Switch: Description and Operation SYSTEM DESCRIPTION The driver door ajar switch is integral to the driver side front door latch. The switch closes a path to ground for the Central Timer Module (CTM) when the driver door is opened, and opens the ground path when the driver door is closed. The driver door ajar switch cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 6883 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Rotate the headlamp switch knob counterclockwise to ensure that the dome lamps are not switched off. Open the driver door and note whether the interior lamps light. They should light. If OK, see Key-In Ignition Switch and/or Headlamp Switch in the Diagnosis and Testing. If not OK, go to Step 2. 2. Disconnect and isolate the battery negative cable. Unplug the driver door latch wire harness connector. Check for continuity between the ground circuit cavity in the body half of the driver door latch wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the circuit to ground as required. 3. Check for continuity between the driver door ajar switch ground circuit terminal and the driver door ajar switch sense circuit terminal of the driver door latch wire harness connector. There should be continuity with the driver door open, and no continuity with the driver door closed. If OK, go to Step 4. If not OK, replace the faulty latch. 4. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the procedures. Unplug the 14-way CTM wire harness connector. Check for continuity between the driver door ajar switch sense circuit cavity of the 14-way CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5 If not OK, repair the short circuit as required. 5. Check for continuity between the driver door ajar switch sense circuit cavities of the 14-way CTM wire harness connector and the driver door latch wire harness connector. There should be continuity. If OK, see Key-In Ignition Switch and/or Headlamp Switch in the Diagnosis and Testing. If not OK, repair the open circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair Fog/Driving Lamp Bulb: Service and Repair REMOVAL 1. Disengage fog lamp harness connector. Fog Lamp Bulb 2. Rotate bulb socket a 1/4 turn counterclockwise and pull from lamp to separate. 3. Grasp bulb and pull from lamp. INSTALLATION CAUTION: Do not touch the bulb glass with fingers or other oily surfaces. Reduced bulb life will result. 1. Position bulb in lamp, push to seat and rotate a 1/4 turn clockwise. 2. Connect fog lamp harness connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 6891 Fog/Driving Lamp Relay: Diagrams Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 6892 Fog Lamp Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations 8w-11-002 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6897 Hazard Warning Flasher: Diagrams Relay And Fuse Box Combination Flasher Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6898 Hazard Warning Flasher: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6899 Hazard Warning Flasher: Description and Operation DESCRIPTION The combination flasher is a smart relay that functions as both the turn signal system and the hazard warning system flasher. 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. While the combination flasher has a International Standards Organization (ISO)-type relay terminal configration or footprint, the internal circuitry is much different. The combination flasher does not use standard ISO-relay inputs or provide ISO-relay type outputs or functions. The combination flasher should never be substituted for an ISO-relay or replaced with an ISO-relay, or else component and vehicle damage may occur. 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 system and hazard warning system circuits. Then replace the combination flasher with a known good unit to confirm system operation. The combination flasher has five blade-type terminals intended for the following inputs and outputs: fused B(+), fused ignition switch output, ground, turn signal circuit, and hazard warning circuit. Constant battery voltage and ground are 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 combination flasher is located in the relay and fuse block which is located on the back of the junction block near the dash panel under the left end of the instrument panel. The combination flasher cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. OPERATION Combination Flasher - Typical The IC within the combination flasher contains the logic that controls the flasher operation and the flash rate. Pin 6 of the IC receives a sense voltage from the hazard warning circuit of the multi-function switch. When the hazard warning switch is turned on, the "hazard on sense voltage will become low due to the circuit being grounded through the turn signal bulbs. This low voltage sense signals the IC to energize the flash control Positive-Negative-Positive (PNP) transistor at a pre-calibrated flash rate or frequency. Each time the PNP transistor energizes the hazard warning circuit, the pin 6 "hazard on sense" voltage will become high and the IC signals the PNP transistor to de-energize the circuit. This cycling will continue until the hazard warning switch is turned off. Likewise, pin 8 of the IC receives a sense voltage from the turn signal circuits of the multi-function switch. When the left or right turn signal switch is turned on, the "turn signal on sense" voltage will become low due to the circuit being grounded through the turn signal bulbs. This low voltage sense signals the IC to energize the flash control PNP transistor at a pre-calibrated flash rate or frequency. Each time the PNP transistor energizes the turn signal circuit, the pin 8 "turn signal on sense" voltage will become high and the IC signals the PNP transistor to de-energize the circuit. This cycling will continue until the right or left turn signal switch is turned off. 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). During turn signal operation, the combination flasher IC compares normal battery voltage input on pin 2 with the shunt resistor voltage input on pin 7. If the IC "senses" that the voltage difference between pin 2 and pin 7 is different than the pre-calibrated value of the IC, it will increase the rate at which it signals the PNP transistor to energize the pin 1 output. Thus, the inoperative half (left or right side) of the turn signal circuit will flash faster. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6900 Hazard Warning Flasher: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover from the instrument panel. Refer to Steering Column Opening Cover/Service and Repair of Instrument Panel Systems for the procedures. Combination Flasher Remove/Install 3. Reach through the outboard side of the steering column opening in the instrument panel to access the relay and fuse block on the back of the junction block. 4. Refer to Fuse Block for combination flasher identification and location. 5. Remove the combination flasher from the relay and fuse block. INSTALLATION 1. Refer to Fuse/Fuse Block for proper combination flasher location. 2. Position the combination flasher in the proper receptacle in the relay and fuse block. 3. Align the combination flasher terminals with the terminal cavities in the relay and fuse block receptacle. 4. Push in firmly on the combination flasher until the terminals are fully seated in the terminal cavities in the relay and fuse block receptacle. 5. Install the steering column opening cover onto the instrument panel. Refer to Steering Column Opening Cover/Service and Repair of Instrument Panel Systems for the procedures. 6. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Specifications Hazard Warning Switch: Specifications Tighten the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle to 2 Nm (17 in. lbs.). Tighten the two screws that secure the multi-function switch to the steering column to 2 Nm (17 in. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Specifications > Page 6904 Multi-Function Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Specifications > Page 6905 Hazard Warning Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Specifications > Page 6906 Hazard Warning Switch: Description and Operation DESCRIPTION Multi-Function Switch The turn signal and hazard warning switches are integral to the multi-function switch unit, which is secured to the left side of the steering column. The only visible parts of the multi-function switch are the control stalk that extends from the left side of the steering column, and the hazard warning switch push button that protrudes from the top of the steering column. The multi-function switch control stalk has both nomenclature and international control symbols on it, which identify its many functions. The hazard warning switch push button is identified with a double triangle, which is the international control symbol for hazard warning. The remainder of the multi-function switch is concealed beneath the steering column shrouds. The multi-function switch also contains circuitry for the following functions: Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information addresses only the multi-function switch turn signal and hazard warning functions. However, the turn signal and hazard warning switches cannot be repaired. If these switches or any other circuit or component of the multi-function switch unit is faulty or damaged, the entire multifunction switch unit must be replaced. OPERATION The hazard warning switch is controlled by the hazard warning switch push button. Push the switch button in to unlatch the switch and activate the hazard warning system, and push in on the button again to latch the switch and turn the system off. When the hazard waring 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Specifications > Page 6907 Hazard Warning Switch: Testing and Inspection The turn signal switch and the hazard warning switch are integral to the multi-function switch. Refer to Turn Signal and Hazard Warning Systems in the Diagnosis and Testing before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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 instrument panel wire harness connector from the multi-function switch connector receptacle. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the connector receptacle terminals as shown in the Multi-Function Switch Continuity chart. 3. If the turn signal switch or hazard warning switch fails any of the continuity checks, replace the faulty multi-function switch assembly as required. If the switch circuits are OK, repair the lighting circuits as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Specifications > Page 6908 Hazard Warning Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt lever from the left side of the steering column. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud from the steering column. Multifunction Switch 5. Move the upper fixed column shroud far enough to access the back of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof Torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the multi-function switch away from the steering column far enough to access and remove the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. 8. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. 9. Remove the multi-function switch from the steering column. INSTALLATION 1. Position the multi-function switch onto the steering column. 2. Reconnect the instrument panel wire harness connector to the multi-function switch connector receptacle. 3. Install and tighten the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. Tighten the screw to 2 Nm (17 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Specifications > Page 6909 4. Install and tighten the two screws that secure the multi-function switch to the steering column. Tighten the screws to 2 Nm (17 in. lbs.) 5. Install the lower fixed column shroud onto the steering column. 6. Install both the upper and lower shrouds onto the steering column. 7. If the vehicle is so equipped, install the tilt lever onto the left side of the steering column. 8. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair REMOVAL 1. Open hood. 2. With-in the engine compartment, remove retaining ring holding bulb to headlamp. Headlamp Bulb 3. Pull bulb socket from headlamp. 4. Grasp bulb and pull from socket. INSTALLATION CAUTION: Do not touch the bulb glass with fingers or other oily surfaces. Reduced bulb life will result. 1. Position bulb into socket and push into place. 2. Position bulb socket in headlamp. 3. Install retaining ring holding bulb to headlamp. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Power Distribution Center The headlamp relay is located in the Power Distribution Center (PDC), behind the battery on the left side of the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 6917 Headlamp Relay: Diagrams Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 6918 Headlamp Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 6919 Headlamp Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 6920 Headlamp Relay: Description and Operation SYSTEM DESCRIPTION The headlamp (or security) relay is a 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay The headlamp relay is a electromechanical device that switches battery current to the headlamps when the high-line Central Timer Module (CTM) grounds the relay coil. See Headlamp Relay Diagnosis and Testing for more information. The headlamp relay is located in the Power Distribution Center (PDC), behind the battery on the left side of the engine compartment. The headlamp relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 6921 Headlamp Relay: Testing and Inspection The headlamp (or security) and horn relays are located in the Power Distribution Center (PDC) in the engine compartment. Each of these relays can be tested as described in the following procedure, however the circuits they are used in do vary To test the relay circuits. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. Relay Terminals 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, test the relay circuits. If not OK, replace the faulty relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 6922 Headlamp Relay: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for headlamp relay identification and location. 4. Unplug the headlamp relay from the PDC. 5. Install the headlamp relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Specifications Headlamp Switch: Specifications Headlamp Switch to Instrument Panel Screws (3) 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Specifications > Page 6926 Headlamp Switch: Locations Headlamp Switch Remove/Install The headlamp switch is located in the instrument panel, outboard of the steering column. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Specifications > Page 6927 Multi-Function Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Specifications > Page 6928 Headlamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Specifications > Page 6929 Headlamp Switch: Description and Operation SYSTEM DESCRIPTION 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). The headlamp switch cannot be repaired and, if faulty or damaged, it must be replaced. Refer to Headlamp Switch/Service and Repair of Instrument Panel Systems for the service procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Specifications > Page 6930 Headlamp Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. Remove the headlamp switch from the instrument panel. Refer to Headlamp Switch/Service and Repair of Instrument Panel Systems for the procedures. Unplug the headlamp switch wire harness connectors. Check for continuity between the driver door ajar switch sense circuit cavity of the headlamp switch wire harness connector and a good ground. There should be continuity with the driver door open, and no continuity with the driver door closed. If OK, go to Step 2. If not OK, repair the circuit to the driver door ajar switch as required. 2. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the procedures. Unplug the 14-way CTM wire harness connector. Remove the key from the ignition lock cylinder. Check for continuity between the key-in ignition switch sense circuit cavity of the 14-way CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 3. If not OK, repair the short circuit as required. 3. Check for continuity between the key-in ignition switch sense circuit cavities of the 14-way CTM wire harness connector and the headlamp switch wire harness connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open circuit as required. 4. Check for continuity between the driver door ajar switch sense circuit terminal and the key-in ignition switch sense circuit terminal of the headlamp switch. There should be no continuity with the switch in the Off position, and continuity with the switch in the park or head lamps On position. If OK, see Central Timer Module in the Diagnosis and Testing. If not OK, replace the faulty headlamp switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Specifications > Page 6931 Headlamp Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. Refer to Cluster Bezel Replacement for the procedures. Headlamp Switch Remove/Install 3. Remove the three screws that secure the headlamp switch to the instrument panel. 4. Pull the headlamp switch away from the instrument panel far enough to access the instrument panel wire harness connectors. 5. Disconnect the two instrument panel wire harness connectors from the headlamp switch connector receptacles. 6. Remove the headlamp switch from the instrument panel. INSTALLATION 1. Position the headlamp switch to the instrument panel. 2. Reconnect the two instrument panel wire harness connectors to the headlamp switch connector receptacles. 3. Install the headlamp switch into the instrument panel. 4. Install and tighten the three screws that secure the headlamp switch to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 5. Install the cluster bezel onto the instrument panel. Refer to Cluster Bezel Replacement for the procedures. 6. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Service Precautions Hi-Beam Indicator Lamp: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Service Precautions > Page 6935 Hi-Beam Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application High Beam Indicator Lamp .................................................................................................................. ............................................................. PC194 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Service Precautions > Page 6936 Hi-Beam Indicator Lamp: Testing and Inspection HARD-WIRED LAMP DIAGNOSIS This lamp depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedure will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS (SUPPLEMENTAL 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. HEADLAMP HIGH BEAM INDICATOR LAMP The diagnosis found here addresses an inoperative headlamp high beam indicator lamp condition. If the problem being diagnosed is related to inoperative headlamp high beams, refer to Headlamp Testing and Inspection. See: Headlamp/Testing and Inspection If no headlamp system problems are found, the following procedure will help locate an open in the high beam indicator lamp circuit. For complete circuit diagrams, refer to Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number 1. Disconnect and isolate the battery negative cable. Remove the instrument cluster. 2. Connect the battery negative cable. Turn the headlamps on and select the high beams with the multi-function switch stalk. Check for battery voltage at the high beam indicator driver circuit cavity of the instrument cluster wire harness connector B. If OK, replace the faulty bulb. If not OK, repair the open high beam indicator driver circuit to the headlamp dimmer (multi-function) switch as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Specifications Horn Relay: Specifications Tighten the screw that secures the horn and mounting bracket unit(s) to the right front inner fender shield to 11 Nm (95 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Specifications > Page 6941 Horn Relay: Locations Power Distribution Center The horn relay is located in the Power Distribution Center (PDC) in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Specifications > Page 6942 Horn Relay: Diagrams Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Specifications > Page 6943 Horn Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Specifications > Page 6944 Horn Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Specifications > Page 6945 Horn Relay: Description and Operation DESCRIPTION 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 Power Distribution Center (PDC) in the engine compartment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the PDC until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the PDC cover 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 horn relay is a 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay The horn relay is a electromechanical device that switches battery current to the horn when the horn switch or the high-line Central Timer Module (CTM) grounds the relay coil. See Horn Relay Testing and Inspection for more information. The horn relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the PDC until further diagnosis is completed. The horn relay cannot be repaired and, if faulty or damaged, it must be replaced. OPERATION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Specifications > Page 6946 Horn Relay: Testing and Inspection The headlamp (or security) and horn relays are located in the Power Distribution Center (PDC) in the engine compartment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the PDC until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the PDC cover for horn relay identification and location. Each of these relays can be tested as described in the following procedure, however the circuits they are used in do vary To test the relay circuits. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. Relay Terminals Remove the relay from the PDC as described 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, test the relay circuits. 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 in the Diagnosis and Testing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Specifications > Page 6947 Horn Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Distribution Center 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 horn relay identification and location. 4. Remove the horn relay from the PDC. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper horn relay location. 2. Position the horn relay in the proper receptacle in the PDC. 3. Align the horn relay terminals with the terminal cavities in the PDC receptacle. 4. Push down firmly on the horn relay until the terminals are fully seated in the terminal cavities in the PDC receptacle. 5. Install the cover onto the PDC. 6. Reconnect the battery negative cable. 8. Test the relay operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations Driver Side Airbag Module Trim Cover And Horn Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 6951 Horn Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 6952 Horn Switch: Description and Operation DESCRIPTION Airbag Trim Cover Remove/Install 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. OPERATION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 6953 Horn Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. 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. If not OK, refer to Steering Column/Service and Repair of Steering for proper installation of the steering column. 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 Power Distribution Center (PDC). 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 PDC 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 PDC. 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 PDC 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Ignition Key Lamp ................................................................................................................................ ................................................................... 53 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Locations License Plate Lamp Bulb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Locations > Page 6961 License Plate Bulb: Service and Repair REMOVAL 1. Remove license plate lamp from rear bumper. License Plate Lamp Bulb 2. Remove bulb socket from lamp. 3. Pull bulb from socket. INSTALLATION 1. Push bulb in socket. 2. Install bulb socket in lamp. 3. Install license plate lamp in rear bumper. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Overhead Console Reading Lamp Bulb Map Light Bulb: Service and Repair Overhead Console Reading Lamp Bulb REMOVAL 1. Using a small flat blade, carefully pry forward edge of reading lamp lens downward from lamp. 2. Disengage lamp lens from pivots on overhead console. 3. Rotate bulb holder and pull bulb from lamp. INSTALLATION 1. Position bulb in lamp and rotate to secure. Reading Lamp Lens 2. Position lamp lens on overhead console. Ensure contact tab on lamp lens is aligned with lamp switch. 3. Carefully press lamp lens onto pivots. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Overhead Console Reading Lamp Bulb > Page 6967 Map Light Bulb: Service and Repair 2nd Seat Dome/Reading Lamp Bulb REMOVAL Lamp Lens 1. Using a small flat blade, pry the center rearward edge of the dome/reading lamp lens downward from lamp. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Locations Park And Turn Signal Lamp Bulb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Locations > Page 6972 Marker Lamp Bulb: Service and Repair REMOVAL 1. Remove park and turn signal lamp. Headlamp Bulb 2. Remove side marker lamp socket from back of lamp. 3. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair Parking Light Bulb: Service and Repair REMOVAL 1. Remove park and turn signal lamp. Park And Turn Signal Lamp Bulb 2. Rotate bulb socket 1/4 turn counterclockwise and pull turn signal lamp socket from back of lamp. 3. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations Daytime Running Lamp Module The Daytime Running Lamp Module is located on the left inner fender Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 6981 Daytime Running Lamp Control Unit: Description and Operation GENERAL INFORMATION The headlamps on vehicles sold in Canada, will go on when the ignition is turned ON. The module must also receive a signal from the engine controller. This provides a constant Lights On condition while the vehicle is rolling. The lamps illuminate at less than 50% of normal intensity. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 6982 Daytime Running Lamp Control Unit: Service and Repair The Daytime Running Lamp Module is located on the left inner fender. REMOVAL Daytime Running Lamp Module 1. Remove the bolt attaching the module to the inner fender. 2. Disconnect the electrical connector. INSTALLATION 1. Connect the electrical connector. 2. Insert the tab on the DRLM into the slot on the left inner fender. 3. Install the bolt attaching the module to the left inner fender. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 6986 Fog/Driving Lamp Relay: Diagrams Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 6987 Fog Lamp Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Power Distribution Center The headlamp relay is located in the Power Distribution Center (PDC), behind the battery on the left side of the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 6991 Headlamp Relay: Diagrams Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 6992 Headlamp Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 6993 Headlamp Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 6994 Headlamp Relay: Description and Operation SYSTEM DESCRIPTION The headlamp (or security) relay is a 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay The headlamp relay is a electromechanical device that switches battery current to the headlamps when the high-line Central Timer Module (CTM) grounds the relay coil. See Headlamp Relay Diagnosis and Testing for more information. The headlamp relay is located in the Power Distribution Center (PDC), behind the battery on the left side of the engine compartment. The headlamp relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 6995 Headlamp Relay: Testing and Inspection The headlamp (or security) and horn relays are located in the Power Distribution Center (PDC) in the engine compartment. Each of these relays can be tested as described in the following procedure, however the circuits they are used in do vary To test the relay circuits. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. Relay Terminals 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, test the relay circuits. If not OK, replace the faulty relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 6996 Headlamp Relay: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for headlamp relay identification and location. 4. Unplug the headlamp relay from the PDC. 5. Install the headlamp relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Specifications Horn Relay: Specifications Tighten the screw that secures the horn and mounting bracket unit(s) to the right front inner fender shield to 11 Nm (95 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Specifications > Page 7000 Horn Relay: Locations Power Distribution Center The horn relay is located in the Power Distribution Center (PDC) in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Specifications > Page 7001 Horn Relay: Diagrams Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Specifications > Page 7002 Horn Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Specifications > Page 7003 Horn Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Specifications > Page 7004 Horn Relay: Description and Operation DESCRIPTION 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 Power Distribution Center (PDC) in the engine compartment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the PDC until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the PDC cover 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 horn relay is a 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay The horn relay is a electromechanical device that switches battery current to the horn when the horn switch or the high-line Central Timer Module (CTM) grounds the relay coil. See Horn Relay Testing and Inspection for more information. The horn relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the PDC until further diagnosis is completed. The horn relay cannot be repaired and, if faulty or damaged, it must be replaced. OPERATION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Specifications > Page 7005 Horn Relay: Testing and Inspection The headlamp (or security) and horn relays are located in the Power Distribution Center (PDC) in the engine compartment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the PDC until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the PDC cover for horn relay identification and location. Each of these relays can be tested as described in the following procedure, however the circuits they are used in do vary To test the relay circuits. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. Relay Terminals Remove the relay from the PDC as described 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, test the relay circuits. 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 in the Diagnosis and Testing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Specifications > Page 7006 Horn Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Distribution Center 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 horn relay identification and location. 4. Remove the horn relay from the PDC. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper horn relay location. 2. Position the horn relay in the proper receptacle in the PDC. 3. Align the horn relay terminals with the terminal cavities in the PDC receptacle. 4. Push down firmly on the horn relay until the terminals are fully seated in the terminal cavities in the PDC receptacle. 5. Install the cover onto the PDC. 6. Reconnect the battery negative cable. 8. Test the relay operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 7010 Trailer Lighting Relay: Diagrams Power Distribution Center Trailer Tow Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Transmission Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Lighting - Stop Lamp Switch Service Revisions Brake Light Switch: Technical Service Bulletins Lighting - Stop Lamp Switch Service Revisions NUMBER: 26-05-99A GROUP: Miscellaneous DATE: May, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1999 Durango Service Manual - Publication Number 81-370-9116 DESCRIPTION OF CHANGES Revisions to the Stop Lamp Switch Service Procedures Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Lighting - Stop Lamp Switch Service Revisions > Page 7019 5-2 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Lighting - Stop Lamp Switch Service Revisions > Page 7020 5-12 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 7021 Brake Lamp Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 7022 Brake Lamp Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > With Antilock Brakes Brake Light Switch: Description and Operation With Antilock Brakes The primary function of the switch is to turn on the stop 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. When the brake light switch is activated, the Powertrain Control Module (PCM) receives an input indicating that the brakes are being applied. After receiving this input, the PCM maintains idle speed to a scheduled rpm through control of the Idle Air Control (IAC) motor. The brake switch input is also used to disable vent and vacuum solenoid output signals to the speed control servo. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > With Antilock Brakes > Page 7025 Brake Light Switch: Description and Operation With Standard Brakes The content of this article reflects the changes called out by TSB 26-05-99. The stop lamp switch is mounted on a bracket on 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 7026 Brake Light Switch: Testing and Inspection The stop lamp switch has a 12 volt feed circuit from the fuse block. Verify fuse is OK, then check the feed from the fuse block to the switch. If the switch has 12 volts depress the brake pedal and check for voltage to the stop lamp circuit. If no voltage is present the switch must be replaced. If the switch does not have 12 volts from the fuse block check for continuity between the fuse block the switch and repair as necessary. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 7027 Brake Light Switch: Service and Repair The content of this article reflects the changes called out by TSB 26-05-99. REMOVAL Stop Lamp Switch & Bracket 1. Disconnect switch harness. 2. Press and hold brake pedal in applied position. 3. Rotate switch counterclockwise about 30° 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. Install switch. Align tab on 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Introduction (Part 1 Of 2) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7032 (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. 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. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component 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 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 Function Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7033 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7034 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 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 In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7035 - 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 connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7036 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7037 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram 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 Shut Down 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. Symbols Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7038 Wiring Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7039 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7040 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7041 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7042 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7043 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7044 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7045 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7046 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7047 Door Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7048 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7049 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7050 Compass/Mini-Trip Computer Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 7051 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 7052 Door Switch: Description and Operation SYSTEM DESCRIPTION The driver door ajar switch is integral to the driver side front door latch. The switch closes a path to ground for the Central Timer Module (CTM) when the driver door is opened, and opens the ground path when the driver door is closed. The driver door ajar switch cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 7053 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Rotate the headlamp switch knob counterclockwise to ensure that the dome lamps are not switched off. Open the driver door and note whether the interior lamps light. They should light. If OK, see Key-In Ignition Switch and/or Headlamp Switch in the Diagnosis and Testing. If not OK, go to Step 2. 2. Disconnect and isolate the battery negative cable. Unplug the driver door latch wire harness connector. Check for continuity between the ground circuit cavity in the body half of the driver door latch wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the circuit to ground as required. 3. Check for continuity between the driver door ajar switch ground circuit terminal and the driver door ajar switch sense circuit terminal of the driver door latch wire harness connector. There should be continuity with the driver door open, and no continuity with the driver door closed. If OK, go to Step 4. If not OK, replace the faulty latch. 4. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the procedures. Unplug the 14-way CTM wire harness connector. Check for continuity between the driver door ajar switch sense circuit cavity of the 14-way CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5 If not OK, repair the short circuit as required. 5. Check for continuity between the driver door ajar switch sense circuit cavities of the 14-way CTM wire harness connector and the driver door latch wire harness connector. There should be continuity. If OK, see Key-In Ignition Switch and/or Headlamp Switch in the Diagnosis and Testing. If not OK, repair the open circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Locations Glove Box Lamp And Switch Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Locations > Page 7057 Glove Box Lamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Locations > Page 7058 Glove Box Lamp Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. REMOVAL 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. 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications Hazard Warning Switch: Specifications Tighten the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle to 2 Nm (17 in. lbs.). Tighten the two screws that secure the multi-function switch to the steering column to 2 Nm (17 in. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 7062 Multi-Function Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 7063 Hazard Warning Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 7064 Hazard Warning Switch: Description and Operation DESCRIPTION Multi-Function Switch The turn signal and hazard warning switches are integral to the multi-function switch unit, which is secured to the left side of the steering column. The only visible parts of the multi-function switch are the control stalk that extends from the left side of the steering column, and the hazard warning switch push button that protrudes from the top of the steering column. The multi-function switch control stalk has both nomenclature and international control symbols on it, which identify its many functions. The hazard warning switch push button is identified with a double triangle, which is the international control symbol for hazard warning. The remainder of the multi-function switch is concealed beneath the steering column shrouds. The multi-function switch also contains circuitry for the following functions: Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information addresses only the multi-function switch turn signal and hazard warning functions. However, the turn signal and hazard warning switches cannot be repaired. If these switches or any other circuit or component of the multi-function switch unit is faulty or damaged, the entire multifunction switch unit must be replaced. OPERATION The hazard warning switch is controlled by the hazard warning switch push button. Push the switch button in to unlatch the switch and activate the hazard warning system, and push in on the button again to latch the switch and turn the system off. When the hazard waring 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 7065 Hazard Warning Switch: Testing and Inspection The turn signal switch and the hazard warning switch are integral to the multi-function switch. Refer to Turn Signal and Hazard Warning Systems in the Diagnosis and Testing before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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 instrument panel wire harness connector from the multi-function switch connector receptacle. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the connector receptacle terminals as shown in the Multi-Function Switch Continuity chart. 3. If the turn signal switch or hazard warning switch fails any of the continuity checks, replace the faulty multi-function switch assembly as required. If the switch circuits are OK, repair the lighting circuits as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 7066 Hazard Warning Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt lever from the left side of the steering column. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud from the steering column. Multifunction Switch 5. Move the upper fixed column shroud far enough to access the back of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof Torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the multi-function switch away from the steering column far enough to access and remove the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. 8. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. 9. Remove the multi-function switch from the steering column. INSTALLATION 1. Position the multi-function switch onto the steering column. 2. Reconnect the instrument panel wire harness connector to the multi-function switch connector receptacle. 3. Install and tighten the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. Tighten the screw to 2 Nm (17 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 7067 4. Install and tighten the two screws that secure the multi-function switch to the steering column. Tighten the screws to 2 Nm (17 in. lbs.) 5. Install the lower fixed column shroud onto the steering column. 6. Install both the upper and lower shrouds onto the steering column. 7. If the vehicle is so equipped, install the tilt lever onto the left side of the steering column. 8. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications Headlamp Switch: Specifications Headlamp Switch to Instrument Panel Screws (3) 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications > Page 7071 Headlamp Switch: Locations Headlamp Switch Remove/Install The headlamp switch is located in the instrument panel, outboard of the steering column. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications > Page 7072 Multi-Function Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications > Page 7073 Headlamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications > Page 7074 Headlamp Switch: Description and Operation SYSTEM DESCRIPTION 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). The headlamp switch cannot be repaired and, if faulty or damaged, it must be replaced. Refer to Headlamp Switch/Service and Repair of Instrument Panel Systems for the service procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications > Page 7075 Headlamp Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. Remove the headlamp switch from the instrument panel. Refer to Headlamp Switch/Service and Repair of Instrument Panel Systems for the procedures. Unplug the headlamp switch wire harness connectors. Check for continuity between the driver door ajar switch sense circuit cavity of the headlamp switch wire harness connector and a good ground. There should be continuity with the driver door open, and no continuity with the driver door closed. If OK, go to Step 2. If not OK, repair the circuit to the driver door ajar switch as required. 2. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the procedures. Unplug the 14-way CTM wire harness connector. Remove the key from the ignition lock cylinder. Check for continuity between the key-in ignition switch sense circuit cavity of the 14-way CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 3. If not OK, repair the short circuit as required. 3. Check for continuity between the key-in ignition switch sense circuit cavities of the 14-way CTM wire harness connector and the headlamp switch wire harness connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open circuit as required. 4. Check for continuity between the driver door ajar switch sense circuit terminal and the key-in ignition switch sense circuit terminal of the headlamp switch. There should be no continuity with the switch in the Off position, and continuity with the switch in the park or head lamps On position. If OK, see Central Timer Module in the Diagnosis and Testing. If not OK, replace the faulty headlamp switch. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications > Page 7076 Headlamp Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. Refer to Cluster Bezel Replacement for the procedures. Headlamp Switch Remove/Install 3. Remove the three screws that secure the headlamp switch to the instrument panel. 4. Pull the headlamp switch away from the instrument panel far enough to access the instrument panel wire harness connectors. 5. Disconnect the two instrument panel wire harness connectors from the headlamp switch connector receptacles. 6. Remove the headlamp switch from the instrument panel. INSTALLATION 1. Position the headlamp switch to the instrument panel. 2. Reconnect the two instrument panel wire harness connectors to the headlamp switch connector receptacles. 3. Install the headlamp switch into the instrument panel. 4. Install and tighten the three screws that secure the headlamp switch to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 5. Install the cluster bezel onto the instrument panel. Refer to Cluster Bezel Replacement for the procedures. 6. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Driver Side Airbag Module Trim Cover And Horn Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 7080 Horn Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 7081 Horn Switch: Description and Operation DESCRIPTION Airbag Trim Cover Remove/Install 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. OPERATION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 7082 Horn Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. 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. If not OK, refer to Steering Column/Service and Repair of Steering for proper installation of the steering column. 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 Power Distribution Center (PDC). 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 PDC 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 PDC. 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 PDC 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications Turn Signal Switch: Specifications Instrument Panel Wiring Harness Connector to Multi-Function Switch Connector Receptacle Screw 17 in.lb Multi-Function Switch to Steering Column Screws (2) 17 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 7086 Multifunction Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 7087 Multi-Function Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 7088 Turn Signal Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 7089 Turn Signal Switch: Description and Operation DESCRIPTION Multi-Function Switch The turn signal and hazard warning switches are integral to the multi-function switch unit, which is secured to the left side of the steering column. The only visible parts of the multi-function switch are the control stalk that extends from the left side of the steering column, and the hazard warning switch push button that protrudes from the top of the steering column. The multi-function switch control stalk has both nomenclature and international control symbols on it, which identify its many functions. The hazard warning switch push button is identified with a double triangle, which is the international control symbol for hazard warning. The remainder of the multi-function switch is concealed beneath the steering column shrouds. The multi-function switch also contains circuitry for the following functions: Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained in this addresses only the multi-function switch turn signal and hazard warning functions. However, the turn signal and hazard warning switches cannot be repaired. If these switches or any other circuit or component of the multi-function switch unit is faulty or damaged, the entire multifunction switch unit must be replaced. OPERATION The multi-function switch control stalk that extends from the left side of the steering column just below the steering wheel is moved up or down to activate the turn signal switch. When the control stalk is moved in the upward direction, the right turn signal switch circuitry is activated; and, when the control stalk is moved in the downward direction, the left turn signal switch circuitry is activated. 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 turn signal switch is in a detent position, it is turned off by one of two turn signal cancelling cam lobes that are integral to the rotor of the clockspring mechanism. Turning the steering wheel causes the turn signal cancelling cam lobes to contact a cancel actuator in the multi-function switch, and the turn signal switch automatically returns to the off position. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 7090 Turn Signal Switch: Testing and Inspection The turn signal switch and the hazard warning switch are integral to the multi-function switch. Refer to Turn Signal and Hazard Warning Systems in the Diagnosis and Testing before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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 instrument panel wire harness connector from the multi-function switch connector receptacle. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the connector receptacle terminals as shown in the Multi-Function Switch Continuity chart. 3. If the turn signal switch or hazard warning switch fails any of the continuity checks, replace the faulty multi-function switch assembly as required. If the switch circuits are OK, repair the lighting circuits as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 7091 Turn Signal Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt lever from the left side of the steering column. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud from the steering column. Multifunction Switch 5. Move the upper fixed column shroud far enough to access the back of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof Torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the multi-function switch away from the steering column far enough to access and remove the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. 8. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. 9. Remove the multi-function switch from the steering column. INSTALLATION 1. Position the multi-function switch onto the steering column. 2. Reconnect the instrument panel wire harness connector to the multi-function switch connector receptacle. 3. Install and tighten the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. Tighten the screw to 2 Nm (17 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 7092 4. Install and tighten the two screws that secure the multi-function switch to the steering column. Tighten the screws to 2 Nm (17 in. lbs.) 5. Install the lower fixed column shroud onto the steering column. 6. Install both the upper and lower shrouds onto the steering column. 7. If the vehicle is so equipped, install the tilt lever onto the left side of the steering column. 8. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Locations Tail, Stop, Turn Signal And Back-Up Lamp Bulbs Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Locations > Page 7097 Tail Light Bulb: Service and Repair REMOVAL 1. Release liftgate latch and open liftgate. 2. Remove screws attaching tail, stop, turn signal and back-up lamp to liftgate opening. 3. Separate inner end of lamp from quarter panel. 4. Disengage hook holding outer end of lamp to quarter panel opening. 5. Separate lamp from quarter panel. Tail, Stop, Turn Signal And Back-Up Lamp Bulbs 6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp. Pull Bulb From Socket 8. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 7101 Trailer Lighting Relay: Diagrams Power Distribution Center Trailer Tow Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Combination Flasher Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 7106 Turn Signal Flasher: Diagrams Relay And Fuse Box Combination Flasher Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 7107 Turn Signal Flasher: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 7108 Turn Signal Flasher: Description and Operation DESCRIPTION The combination flasher is a smart relay that functions as both the turn signal system and the hazard warning system flasher. 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. While the combination flasher has a International Standards Organization (ISO)-type relay terminal configuration or footprint, the internal circuitry is much different. The combination flasher does not use standard ISO-relay inputs or provide ISO-relay type outputs or functions. The combination flasher should never be substituted for an ISO-relay or replaced with an ISO-relay, or else component and vehicle damage may occur. 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 system and hazard warning system circuits. Then replace the combination flasher with a known good unit to confirm system operation. The combination flasher has five blade-type terminals intended for the following inputs and outputs: fused B(+), fused ignition switch output, ground, turn signal circuit, and hazard warning circuit. Constant battery voltage and ground are 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 combination flasher is located in the relay and fuse block which is located on the back of the junction block near the dash panel under the left end of the instrument panel. The combination flasher cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. OPERATION Multi-Function Switch The IC within the combination flasher contains the logic that controls the flasher operation and the flash rate. Pin 6 of the IC receives a sense voltage from the hazard warning circuit of the multifunction switch. When the hazard warning switch is turned on, the "hazard on sense voltage will become low due to the circuit being grounded through the turn signal bulbs. This low voltage sense signals the IC to energize the flash control Positive-Negative- Positive (PNP) transistor at a pre-calibrated flash rate or frequency. Each time the PNP transistor energizes the hazard warning circuit, the pin 6 "hazard on sense" voltage will become high and the IC signals the PNP transistor to de-energize the circuit. This cycling will continue until the hazard warning switch is turned off. Likewise, pin 8 of the IC receives a sense voltage from the turn signal circuits of the multi-function switch. When the left or right turn signal switch is turned on, the "turn signal on sense" voltage will become low due to the circuit being grounded through the turn signal bulbs. This low voltage sense signals the IC to energize the flash control PNP transistor at a pre-calibrated flash rate or frequency. Each time the PNP transistor energizes the turn signal circuit, the pin 8 "turn signal on sense" voltage will become high and the IC signals the PNP transistor to de-energize the circuit. This cycling will continue until the right or left turn signal switch is turned off. 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). During turn signal operation, the combination flasher IC compares normal battery voltage input on pin 2 with the shunt resistor voltage input on pin 7. If the IC "senses" that the voltage difference between pin 2 and pin 7 is different than the pre-calibrated value of the IC, it will increase the rate at which it signals the PNP transistor to energize the pin 1 output. Thus, the inoperative half (left or right side) of the turn signal circuit will flash faster. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 7109 Turn Signal Flasher: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover from the instrument panel. Refer to Steering Column Opening Cover/Service and Repair of Instrument Panel Systems for the procedures. Combination Flasher Remove/Install 3. Reach through the outboard side of the steering column opening in the instrument panel to access the relay and fuse block on the back of the junction block. 4. Refer to Fuse Block for combination flasher identification and location. 5. Remove the combination flasher from the relay and fuse block. INSTALLATION 1. Refer to Fuse/Fuse Block for proper combination flasher location. 2. Position the combination flasher in the proper receptacle in the relay and fuse block. 3. Align the combination flasher terminals with the terminal cavities in the relay and fuse block receptacle. 4. Push in firmly on the combination flasher until the terminals are fully seated in the terminal cavities in the relay and fuse block receptacle. 5. Install the steering column opening cover onto the instrument panel. Refer to Steering Column Opening Cover/Service and Repair of Instrument Panel Systems for the procedures. 6. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Service Precautions Turn Signal Indicator: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Service Precautions > Page 7113 Turn Signal Indicator: Testing and Inspection HARD-WIRED LAMP DIAGNOSIS This lamp depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedure will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS (SUPPLEMENTAL 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. TURN SIGNAL INDICATOR LAMP The diagnosis found here addresses an inoperative turn signal indicator lamp condition. For any other turn signal problem, refer to Turn Signal Testing and Inspection for further diagnosis. See: Testing and Inspection If no turn signal or hazard warning system problem is found, the following procedure will help locate a short or open in the indicator lamp circuit. For complete circuit diagrams, refer to Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number 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 cluster wire harness connector B. There should be a switching (on and off) battery voltage signal. If OK, replace the faulty (right or left) turn signal indicator lamp bulb. If not OK, repair the open (right or left) turn signal circuit to the turn signal/hazard warning (multi-function) switch as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Locations Tail, Stop, Turn Signal And Back-Up Lamp Bulbs Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Park and Turn Signal Lamp Bulb Turn Signal Bulb: Service and Repair Park and Turn Signal Lamp Bulb REMOVAL 1. Remove park and turn signal lamp. Park And Turn Signal Lamp Bulb 2. Rotate bulb socket 1/4 turn counterclockwise and pull turn signal lamp socket from back of lamp. 3. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Park and Turn Signal Lamp Bulb > Page 7120 Turn Signal Bulb: Service and Repair Tail, Stop, Turn Signal and Back-Up Lamp Bulb REMOVAL 1. Release liftgate latch and open liftgate. 2. Remove screws attaching tail, stop, turn signal and back-up lamp to liftgate opening. 3. Separate inner end of lamp from quarter panel. 4. Disengage hook holding outer end of lamp to quarter panel opening. 5. Separate lamp from quarter panel. Tail, Stop, Turn Signal And Back-Up Lamp Bulbs 6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp. Pull Bulb From Socket 8. 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications Turn Signal Switch: Specifications Instrument Panel Wiring Harness Connector to Multi-Function Switch Connector Receptacle Screw 17 in.lb Multi-Function Switch to Steering Column Screws (2) 17 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications > Page 7124 Multifunction Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications > Page 7125 Multi-Function Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications > Page 7126 Turn Signal Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications > Page 7127 Turn Signal Switch: Description and Operation DESCRIPTION Multi-Function Switch The turn signal and hazard warning switches are integral to the multi-function switch unit, which is secured to the left side of the steering column. The only visible parts of the multi-function switch are the control stalk that extends from the left side of the steering column, and the hazard warning switch push button that protrudes from the top of the steering column. The multi-function switch control stalk has both nomenclature and international control symbols on it, which identify its many functions. The hazard warning switch push button is identified with a double triangle, which is the international control symbol for hazard warning. The remainder of the multi-function switch is concealed beneath the steering column shrouds. The multi-function switch also contains circuitry for the following functions: Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained in this addresses only the multi-function switch turn signal and hazard warning functions. However, the turn signal and hazard warning switches cannot be repaired. If these switches or any other circuit or component of the multi-function switch unit is faulty or damaged, the entire multifunction switch unit must be replaced. OPERATION The multi-function switch control stalk that extends from the left side of the steering column just below the steering wheel is moved up or down to activate the turn signal switch. When the control stalk is moved in the upward direction, the right turn signal switch circuitry is activated; and, when the control stalk is moved in the downward direction, the left turn signal switch circuitry is activated. 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 turn signal switch is in a detent position, it is turned off by one of two turn signal cancelling cam lobes that are integral to the rotor of the clockspring mechanism. Turning the steering wheel causes the turn signal cancelling cam lobes to contact a cancel actuator in the multi-function switch, and the turn signal switch automatically returns to the off position. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications > Page 7128 Turn Signal Switch: Testing and Inspection The turn signal switch and the hazard warning switch are integral to the multi-function switch. Refer to Turn Signal and Hazard Warning Systems in the Diagnosis and Testing before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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 instrument panel wire harness connector from the multi-function switch connector receptacle. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the connector receptacle terminals as shown in the Multi-Function Switch Continuity chart. 3. If the turn signal switch or hazard warning switch fails any of the continuity checks, replace the faulty multi-function switch assembly as required. If the switch circuits are OK, repair the lighting circuits as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications > Page 7129 Turn Signal Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt lever from the left side of the steering column. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud from the steering column. Multifunction Switch 5. Move the upper fixed column shroud far enough to access the back of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof Torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the multi-function switch away from the steering column far enough to access and remove the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. 8. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. 9. Remove the multi-function switch from the steering column. INSTALLATION 1. Position the multi-function switch onto the steering column. 2. Reconnect the instrument panel wire harness connector to the multi-function switch connector receptacle. 3. Install and tighten the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. Tighten the screw to 2 Nm (17 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications > Page 7130 4. Install and tighten the two screws that secure the multi-function switch to the steering column. Tighten the screws to 2 Nm (17 in. lbs.) 5. Install the lower fixed column shroud onto the steering column. 6. Install both the upper and lower shrouds onto the steering column. 7. If the vehicle is so equipped, install the tilt lever onto the left side of the steering column. 8. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Light Bulb > Component Information > Service and Repair Underhood Light Bulb: Service and Repair REMOVAL 1. Insert a small flat blade in the access slot between the lamp base and lamp lens. Underhood Lamp Lens 2. Pry the lamp lens upward and remove the lamp lens. Underhood Lamp Bulb 3. Depress the bulb terminal inward to release the bulb. INSTALLATION 1. Engage the replacement bulb wire loop to the terminal closest to the lamp base wire connector. 2. Depress the opposite terminal inward and engage the remaining bulb wire loop. 3. Position the lamp lens on the lamp base and press into place. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Specifications Rear Window Defogger Switch: Specifications Tighten the Defogger Switch mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Specifications > Page 7140 Rear Window Defogger Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Specifications > Page 7141 Rear Window Defogger Switch: Description and Operation SYSTEM DESCRIPTION The rear window defogger switch is integral to the rear window switch pod, which includes the rear wiper and washer switches. The rear window switch pod is installed in the instrument panel lower bezel which is located near the center of the lower instrument panel, below the heater and air conditioner controls. The rear window switch pod 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 pod cannot be repaired. If any function of the switch pod except lighting is faulty or damaged, the entire switch pod must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Specifications > Page 7142 Rear Window Defogger Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. Remove the lower bezel from the instrument panel and unplug the rear window switch pod wire harness connector. 2. Check for continuity between the ground circuit cavity of the rear window switch pod 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 pod 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 pod. 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 rear window switch pod. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Specifications > Page 7143 Rear Window Defogger Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. 2. Remove the lower bezel from the instrument panel. See Instrument Panel Lower Bezel/Service and Repair of Instrument Panel Systems for the procedures. Rear Window Switch Pod Remove/Install 3. Remove the two screws that secure the rear window switch pod to the instrument panel lower bezel. 4. Remove the rear window switch pod from the instrument panel lower bezel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Specifications Rear Window Defogger Switch: Specifications Tighten the Defogger Switch mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Specifications > Page 7148 Rear Window Defogger Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Specifications > Page 7149 Rear Window Defogger Switch: Description and Operation SYSTEM DESCRIPTION The rear window defogger switch is integral to the rear window switch pod, which includes the rear wiper and washer switches. The rear window switch pod is installed in the instrument panel lower bezel which is located near the center of the lower instrument panel, below the heater and air conditioner controls. The rear window switch pod 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 pod cannot be repaired. If any function of the switch pod except lighting is faulty or damaged, the entire switch pod must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Specifications > Page 7150 Rear Window Defogger Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. Remove the lower bezel from the instrument panel and unplug the rear window switch pod wire harness connector. 2. Check for continuity between the ground circuit cavity of the rear window switch pod 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 pod 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 pod. 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 rear window switch pod. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Specifications > Page 7151 Rear Window Defogger Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. 2. Remove the lower bezel from the instrument panel. See Instrument Panel Lower Bezel/Service and Repair of Instrument Panel Systems for the procedures. Rear Window Switch Pod Remove/Install 3. Remove the two screws that secure the rear window switch pod to the instrument panel lower bezel. 4. Remove the rear window switch pod from the instrument panel lower bezel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications Power Window Switch: Specifications Power Window Motor Mounting Screws 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications > Page 7155 Driver Power Window/Door Lock Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications > Page 7156 Power Window Switch: Description and Operation SYSTEM OPERATION The power windows are controlled by four two-way switches and a power window lockout switch that are integral to the power window and lock switch unit on the driver side front door trim panel. Additionally, each of the passenger doors has a single gang two-way power window switch mounted in a bezel on their respective door trim panels. 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. The power window switch for the driver side front door 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 side front door power window and lock switch unit. 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 side master switch unit. When the power window lockout switch is in the Lock position, the battery feed for the individual passenger door power window switches is interrupted. The driver side power window and lock switch unit and the single gang passenger door power window switches cannot be repaired and, if faulty or damaged, the entire switch unit or switch must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications > Page 7157 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, perform the diagnosis for Power Window System. 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. Unplug the wire harness connector from the switch unit. Power Window Switch Continuity - Driver Side Front Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications > Page 7158 Power Window Switch Continuity - Passenger Doors 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, see Power Window Motor in the Diagnosis and Testing. If not OK, replace the faulty switch. NOTE: Because this switch contains active electronic elements for the Auto-down feature, this switch function cannot be checked with a continuity test. If the problem being diagnosed involves this function, reconnect the switch to its wire harness connector, connect the battery negative cable and turn the ignition switch to the On position. Back probe the wire harness connector cavity for switch pin number 8 and check for the proper switch output while actuating the switch. With the switch in the Up position, there should be continuity to ground at pin 8. With the switch in the Down position, there should be battery voltage at pin 8. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications > Page 7159 Power Window Switch: Service and Repair REMOVAL Driver Side Front Door 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the driver side front door. 3. From the back side of the trim panel, remove the screws that secure the power window and lock switch unit to the switch bezel in the door trim panel opening. 4. Remove the power window and lock switch and the switch bezel from the door trim panel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Passenger Door 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the front or rear passenger door. 3. With a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power window switch receptacle on the back of the door trim panel switch bezel and pull the switch out of the receptacle. 4. Reverse the removal procedures to install. Be certain that both of the switch snap retainers in the receptacle on the back of the door trim panel switch bezel are fully engaged. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Description and Operation Power Window Circuit Breaker: Description and Operation SYSTEM DESCRIPTION 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Description and Operation > Page 7164 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, see Power Window System in the Diagnosis and Testing. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams Passenger Door Window Motor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Page 7168 Power Window Motor: Description and Operation SYSTEM OPERATION 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Page 7169 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Page 7170 Power Window Motor: Service and Repair 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Specifications Power Window Switch: Specifications Power Window Motor Mounting Screws 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Specifications > Page 7174 Driver Power Window/Door Lock Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Specifications > Page 7175 Power Window Switch: Description and Operation SYSTEM OPERATION The power windows are controlled by four two-way switches and a power window lockout switch that are integral to the power window and lock switch unit on the driver side front door trim panel. Additionally, each of the passenger doors has a single gang two-way power window switch mounted in a bezel on their respective door trim panels. 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. The power window switch for the driver side front door 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 side front door power window and lock switch unit. 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 side master switch unit. When the power window lockout switch is in the Lock position, the battery feed for the individual passenger door power window switches is interrupted. The driver side power window and lock switch unit and the single gang passenger door power window switches cannot be repaired and, if faulty or damaged, the entire switch unit or switch must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Specifications > Page 7176 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, perform the diagnosis for Power Window System. 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. Unplug the wire harness connector from the switch unit. Power Window Switch Continuity - Driver Side Front Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Specifications > Page 7177 Power Window Switch Continuity - Passenger Doors 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, see Power Window Motor in the Diagnosis and Testing. If not OK, replace the faulty switch. NOTE: Because this switch contains active electronic elements for the Auto-down feature, this switch function cannot be checked with a continuity test. If the problem being diagnosed involves this function, reconnect the switch to its wire harness connector, connect the battery negative cable and turn the ignition switch to the On position. Back probe the wire harness connector cavity for switch pin number 8 and check for the proper switch output while actuating the switch. With the switch in the Up position, there should be continuity to ground at pin 8. With the switch in the Down position, there should be battery voltage at pin 8. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Specifications > Page 7178 Power Window Switch: Service and Repair REMOVAL Driver Side Front Door 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the driver side front door. 3. From the back side of the trim panel, remove the screws that secure the power window and lock switch unit to the switch bezel in the door trim panel opening. 4. Remove the power window and lock switch and the switch bezel from the door trim panel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Passenger Door 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the front or rear passenger door. 3. With a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power window switch receptacle on the back of the door trim panel switch bezel and pull the switch out of the receptacle. 4. Reverse the removal procedures to install. Be certain that both of the switch snap retainers in the receptacle on the back of the door trim panel switch bezel are fully engaged. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair Back 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Page 7183 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Glass Run Weatherstrip 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Glass Run Weatherstrip > Page 7189 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Glass Run Weatherstrip > Page 7190 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 Glass Run Weatherstrip > Page 7191 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 7200 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 7201 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 7202 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 7207 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 7211 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Service and Repair > Front Door Glass Run Window Seal: Service and Repair Front Door Glass Run REMOVAL 1. Remove door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors 2. Remove water dam as necessary to access lower glass run channels. 3. Remove the bolts attaching the glass run channels. 4. Remove glass. See: Window Glass/Front Door Window Glass/Service and Repair/Procedures 5. Pull the glass run weatherstrip and run channels from the window opening. 6. 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. See: Window Glass/Front Door Window Glass/Service and Repair/Procedures 5. Install the glass run channels. See: Window Track/Service and Repair 6. Install inner belt weatherstrip. See: 7. Install outer belt weatherstrip. See: 8. Install door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Service and Repair > Front Door Glass Run > Page 7216 Window Seal: Service and Repair Front Door Inner Belt REMOVAL 1. Remove screws attaching trim panel to door. 2. Lift trim panel up and over inner belt seal. 3. Peel seal from door. INSTALLATION 1 Slide seal into position on door. 2. Position trim panel over inner belt seal and install screws. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Service and Repair > Front Door Glass Run > Page 7217 Window Seal: Service and Repair Front Door Outer Belt REMOVAL 1. Lower glass. 2. Lift rearward comer of weatherstrip and slide weatherstrip rearward. INSTALLATION 1. Lightly lubricate weatherstrip with silicone and slide weatherstrip behind mirror. 2. Push weatherstrip down to seat onto door. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair Window Track: Service and Repair REMOVAL 1. Remove trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors 2. Remove water dam as necessary to access lower run channels. 3. Remove bolts attaching lower glass run channels to door panel. 4. Remove glass. See: Window Glass/Front Door Window Glass/Service and Repair/Procedures 5. Slide lower run channels downward to disengage from upper run channels. 6. Remove lower run channels from door. INSTALLATION 1. Position lower run channels in door. 2. Slide lower run channels upward to engage into upper run channels. 3. Install glass. See: Window Glass/Front Door Window Glass/Service and Repair/Procedures 4. Install bolts attaching lower glass run channels to door panel. 5. Install water dam. See: Body and Frame/Doors, Hood and Trunk/Doors 6. Install trim panel. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 7224 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 7225 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 7226 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Service and Repair Check Valve: Service and Repair REMOVAL AND INSTALLATION A check valve is located in the washer supply hose near the top of the right liftgate opening pillar. 1. Remove the right upper D-pillar trim. 2. Disconnect the washer supply hoses from the barbed nipples on each end of the rear washer system check valve. 3. Remove the check valve from the vehicle. Rear Washer System Check Valve 4. when reinstalling the check valve, be certain the valve is properly oriented within the system flow. 5. Reverse the remaining removal procedures to complete the installation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 The intermittent wipe relay is located in the Power Distribution Center (PDC), in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7235 Wiper Relay: Diagrams Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7236 Wiper Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7237 Wiper Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN,OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7238 Wiper Relay: Description and Operation SYSTEM OPERATION The intermittent wipe relay is a 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The intermittent wipe relay is a electromechanical device that switches battery current to the windshield wiper motor or wiper motor park switch when the relay coil is grounded by the Central Timer Module (CTM) in response to inputs from the windshield wiper (multi-function) switch. See Testing and Inspection. The intermittent wipe relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. The intermittent wipe relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7239 Wiper Relay: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN,OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Relay Test Intermittent Wipe Relay The intermittent wipe relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for intermittent wipe relay identification and location. Remove the intermittent wipe relay from the PDC as described in the Service and Repair 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 Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the wiper (multi-function) switch. There should be continuity between the cavity for relay terminal 30 and the two fused ignition switch output circuit cavities of the multi-function switch wire harness connector at all times. If OK, go to Step 2. If not OK, repair the open circuit(s) to the multi-function switch as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position. There should be continuity between the cavity for relay terminal 87A and the wiper park switch sense circuit cavities of the wiper motor wire harness connector and the 14-way Central Timer Module (CTM) wire harness connector at all times. If OK, go to Step 3. If not OK, repair the open circuit(s) to the wiper motor and CTM as required. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. There should be battery voltage at the cavity for relay terminal 87 with the ignition switch in the On or Accessory positions. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the On or Accessory positions. If OK, go to Step 5. If not OK, repair the open circuit to the ignition switch as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay It is grounded by the CTM to energize the relay and cycle the wiper motor. Check for continuity between the cavity for relay terminal 85 and the intermittent wiper relay control circuit cavity of the 14-way CTM wire harness connector. There should be continuity. If OK, replace the faulty base version CTM; or, use a DRB scan tool and the proper Diagnostic Procedures for diagnosis of the high-line version CTM. If not OK, repair the open circuit to the CTM as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7240 Wiper Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC cover for intermittent wipe relay identification and location. 4. Unplug the intermittent wipe relay from the PDC. 5. Install the intermittent wipe relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation Washer Fluid Level Switch: Description and Operation SYSTEM OPERATION The standard washer fluid level sensor is mounted on the inboard side and near the front of the windshield washer reservoir. A barbed nipple on the sensor is press-fit into a rubber grommet seal installed in a hole in the side of the reservoir. When the fluid level in the reservoir falls below the pivoting float on the sensor, the float changes position and closes the internal switch contacts of the sensor. Refer to Low Washer Fluid Warning Lamp in the Diagnosis and Testing of Instrument Panel Systems for diagnosis of the low washer fluid warning lamp and circuit, including the sensor. The washer fluid level sensor cannot be repaired. If faulty or damaged, the sensor unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Page 7245 Washer Fluid Level Switch: Service and Repair REMOVAL AND INSTALLATION 1. Remove the washer reservoir from the engine compartment. See Washer Reservoir/Service and Repair for the procedures. NOTE: The pivoting float of the washer fluid sensor must be in a horizontal position within the reservoir in order to be removed With the reservoir empty and held in an upright position, the pivoting float will orient itself to the horizontal position when the sensor connector is pointed straight downwards. 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry the washer fluid level sensor out of the rubber grommet seal. Care must be taken not to damage the reservoir. 3. Remove the rubber grommet seal from the reservoir and discard. 4. Reverse the removal procedures to install. Always use a new rubber grommet seal on the reservoir. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications Windshield Washer Switch: Specifications Wiper/Washer Mounting Screws 20 in.lb Multi-Function Switch Wiring Harness Connector Screw 17 in.lb Multi-Function Switch Mounting Screws (2) 17 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7249 Windshield Washer Switch: Locations The windshield wiper and washer switches are contained in the multi-function switch assembly which is secured to the left side of the steering column. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7250 Multi-Function Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7251 Windshield Washer Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AN AIR-BAG, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7252 Windshield Washer Switch: Description and Operation SYSTEM OPERATION Front Multi-Function Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay, or depressed toward the steering column to activate the washer system. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained in this addresses only the switch functions for the windshield wiper and washer systems. For information relative to the other switch functions. However, the multi-function switch cannot be repaired. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Rear The single two-function rear wiper and washer switch is integral to the rear window switch pod, which includes the rear window defogger switch. The rear window switch pod is installed in the instrument panel lower bezel, which is located near the center of the lower instrument panel, below the heater and air conditioner controls. The rear wiper and washer switch controls the rear wiper and washer functions. The rear window switch pod 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 sliding-type switch features a detent in the On position for the rear wiper. Pushing in on the rear wiper switch button activates the momentary rear washer switch. The rear wiper and washer switch also has an integral illumination lamp with a serviceable bulb. Both the rear wiper and rear washer motors will operate continuously for as long as the switch is held in the momentary Wash position. The rear wiper and washer switch cannot be repaired and, if faulty or damaged, the entire rear window switch pod must be replaced. Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module and an illuminated entry module into a single unit. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7253 allows the addition of many new feature capabilities. Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-afterwash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermittent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. Refer to Central Timer module/Service and Repair of Instrument Panel Systems for the service procedures. See Wiper System Testing and Inspection for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7254 Windshield Washer Switch: Testing and Inspection Front See Wiper System and/or Washer System Testing and Inspection before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AN AIR-BAG, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. Unplug the multi-function switch wire harness connector from the multi-function switch. Multi-Function Switch Continuity 3. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 4. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required. Rear Perform the diagnosis for the rear wiper system and/or washer system as described before testing the rear wiper and washer switch. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the lower bezel from the instrument panel and unplug the rear window switch pod wire harness connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7255 Rear Wiper Switch And Washer Switch Continuity 2. Using an ohmmeter, check the rear wiper and washer switch continuity at the rear window switch pod terminals as shown in the Rear Wiper Switch and Washer Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty rear window switch pod. If the switch is OK, repair the rear wiper system and/or washer system wire harness circuits as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7256 Windshield Washer Switch: Service and Repair REMOVAL AND INSTALLATION Front WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multifunction Switch 5. Move the upper fixed column shroud far enough to access the rear of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the switch away from the steering column far enough to access and remove the multifunction switch wire harness connector screw. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: Multi-function switch wire harness connector screw -2 Nm (17 in. lbs.) - Multi-function switch mounting screws - 2 Nm (17 in. lbs.). Rear Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7257 WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. 2. Remove the lower bezel from the instrument panel. Refer to Instrument Panel Lower Bezel/Service and Repair of Instrument Panel Systems for the procedures. Rear Window Switch Pod Remove/Install 3. Remove the two screws that secure the rear window switch pod to the instrument panel lower bezel. 4. Remove the rear window switch pod from the instrument panel lower bezel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications Wiper Switch: Specifications Tighten the fasteners as follows: Multi-function switch wire harness connector screw 2 Nm (17 in. lbs.) Multi-function switch mounting screws 2 Nm (17 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 7261 Wiper Switch: Locations The windshield wiper and washer switches are contained in the multi-function switch assembly which is secured to the left side of the steering column. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 7262 Multi-Function Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 7263 Wiper Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AN AIR-BAG, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 7264 Wiper Switch: Description and Operation SYSTEM OPERATION Front Multi-Function Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay, or depressed toward the steering column to activate the washer system. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information addresses only the switch functions for the windshield wiper and washer systems. However, the multi-function switch cannot be repaired. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Rear The single two-function rear wiper and washer switch is integral to the rear window switch pod, which includes the rear window defogger switch. The rear window switch pod is installed in the instrument panel lower bezel, which is located near the center of the lower instrument panel, below the heater and air conditioner controls. The rear wiper and washer switch controls the rear wiper and washer functions. The rear window switch pod 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 sliding-type switch features a detent in the On position for the rear wiper. Pushing in on the rear wiper switch button activates the momentary rear washer switch. The rear wiper and washer switch also has an integral illumination lamp with a serviceable bulb. Both the rear wiper and rear washer motors will operate continuously for as long as the switch is held in the momentary Wash position. The rear wiper and washer switch cannot be repaired and, if faulty or damaged, the entire rear window switch pod must be replaced. Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module and an illuminated entry module into a single unit. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 7265 Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-afterwash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermittent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the service procedures. See Wiper System Testing and Inspection for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 7266 Wiper Switch: Testing and Inspection Front See Wiper System and/or Washer System Testing and Inspection before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AN AIR-BAG, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. Unplug the multi-function switch wire harness connector from the multi-function switch. Multi-Function Switch Continuity 3. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 4. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required. Rear Perform the diagnosis for the rear wiper system and/or washer system as described before testing the rear wiper and washer switch. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the lower bezel from the instrument panel and unplug the rear window switch pod wire harness connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 7267 Rear Wiper Switch And Washer Switch Continuity 2. Using an ohmmeter, check the rear wiper and washer switch continuity at the rear window switch pod terminals as shown in the Rear Wiper Switch and Washer Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty rear window switch pod. If the switch is OK, repair the rear wiper system and/or washer system wire harness circuits as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 7268 Wiper Switch: Service and Repair REMOVAL AND INSTALLATION Front WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multifunction Switch 5. Move the upper fixed column shroud far enough to access the rear of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the switch away from the steering column far enough to access and remove the multifunction switch wire harness connector screw. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: a. Multi-function switch wire harness connector screw - 2 Nm (17 in. lbs.) b. Multi-function switch mounting screws - 2 Nm (17 in. lbs.). Rear Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 7269 WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. 2. Remove the lower bezel from the instrument panel. Refer to Instrument Panel Lower Bezel/Service and Repair of Instrument Panel Systems for the procedures. Rear Window Switch Pod Remove/Install 3. Remove the two screws that secure the rear window switch pod to the instrument panel lower bezel. 4. Remove the rear window switch pod from the instrument panel lower bezel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Service Precautions Washer Fluid Level Indicator: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Service Precautions > Page 7273 Washer Fluid Level Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Low Washer Fluid Lamp ...................................................................................................................... ............................................................. PC194 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Service Precautions > Page 7274 Washer Fluid Level Indicator: Testing and Inspection HARD-WIRED LAMP DIAGNOSIS This lamp depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedure will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS (SUPPLEMENTAL 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. LOW WASHER FLUID WARNING LAMP The diagnosis found here addresses an inoperative low washer fluid warning lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or washer fluid level sensor and not with a damaged or empty washer fluid reservoir. Inspect the reservoir for proper fluid level and signs of damage or distortion that could affect sensor performance before you proceed with lamp diagnosis. Refer to Washer System Testing and Inspection for more information. See: Testing and Inspection/Component Tests and General Diagnostics/Washer System For complete circuit diagrams, refer to Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number 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 the wire harness connector from the washer fluid level sensor. Install a jumper wire between the two cavities of the washer fluid level sensor wire harness connector. Turn the ignition switch to the ON position. The low washer fluid warning lamp should light. Remove the jumper wire and the lamp should go off. If OK, replace the faulty washer fluid level sensor. If not OK, go to Step 4. 4. Turn the ignition switch to the OFF position. Check for continuity between the ground circuit cavity of the washer fluid level sensor wire harness connector 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. Disconnect and isolate the battery negative cable. Remove the instrument cluster. The washer fluid level sensor wire harness connector is still disconnected. Check for continuity between the low washer fluid level sense circuit cavity of the instrument cluster wire harness connector B and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted low washer fluid level sense circuit as required. 6. Check for continuity between the low washer fluid level sense circuit cavities of the instrument cluster wire harness connector B and the washer fluid level sensor wire harness connector. There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open low washer fluid level sense circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation Washer Fluid Level Switch: Description and Operation SYSTEM OPERATION The standard washer fluid level sensor is mounted on the inboard side and near the front of the windshield washer reservoir. A barbed nipple on the sensor is press-fit into a rubber grommet seal installed in a hole in the side of the reservoir. When the fluid level in the reservoir falls below the pivoting float on the sensor, the float changes position and closes the internal switch contacts of the sensor. Refer to Low Washer Fluid Warning Lamp in the Diagnosis and Testing of Instrument Panel Systems for diagnosis of the low washer fluid warning lamp and circuit, including the sensor. The washer fluid level sensor cannot be repaired. If faulty or damaged, the sensor unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Page 7278 Washer Fluid Level Switch: Service and Repair REMOVAL AND INSTALLATION 1. Remove the washer reservoir from the engine compartment. See Washer Reservoir/Service and Repair for the procedures. NOTE: The pivoting float of the washer fluid sensor must be in a horizontal position within the reservoir in order to be removed With the reservoir empty and held in an upright position, the pivoting float will orient itself to the horizontal position when the sensor connector is pointed straight downwards. 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry the washer fluid level sensor out of the rubber grommet seal. Care must be taken not to damage the reservoir. 3. Remove the rubber grommet seal from the reservoir and discard. 4. Reverse the removal procedures to install. Always use a new rubber grommet seal on the reservoir. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations Windshield Washer Pump: Locations Rear Washer Reservoir Remove/Install The washer pumps and motors are mounted near the bottom of their respective windshield or rear window washer reservoir. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 7282 Windshield Washer Pump: Description and Operation SYSTEM OPERATION The washer pumps and motors are mounted near the bottom of their respective windshield or rear window washer reservoir. A barbed nipple on the pump housing passes through a rubber grommet seal installed in a hole near the bottom of the reservoir. The washer pump is retained by an interference fit between the barbed pump nipple and the grommet seal, which is a light press fit. A permanently lubricated and sealed motor is coupled to a rotor-type pump. Washer fluid is gravity-fed from the reservoir to the pump. When the motor is energized, the pump pressurizes the washer fluid and forces it through the plumbing to the nozzles. The washer pump and motor units cannot be repaired. If faulty, the entire washer pump and motor unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 7283 Windshield Washer Pump: Service and Repair REMOVAL AND INSTALLATION Front 1. Remove the washer reservoir from the engine compartment. See Washer Reservoir/Service and Repair for the procedures. 2. 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. 3. Remove the rubber grommet seal from the reservoir and discard. 4. Reverse the removal procedures to install. Always use a new rubber grommet seal on the reservoir. Rear 1. Remove the washer reservoir from the passenger compartment. See Washer Reservoir/Service and Repair for the procedures. 2. 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. 3. Remove the rubber grommet seal from the reservoir and discard. 4. Reverse the removal procedures to install. Always use a new rubber grommet seal on the reservoir. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications Windshield Washer Reservoir: Specifications Front Reservoir Mounting Screws 24 in.lb Rear Reservoir Mounting Screws 20 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 7287 Windshield Washer Reservoir: Description and Operation SYSTEM OPERATION Front The windshield washer fluid reservoir is secured to the right side of the dash panel and to the right inner fender shield in the engine compartment. The washer pump and motor unit has a barbed nipple, which is installed through a rubber grommet seal inserted in a hole near the bottom of the reservoir. The washer pump is retained by an interference fit between the barbed nipple and the grommet seal, which is a light press fit. The washer reservoir has a snap-fit filler cap with a rubber gasket. The cap hinges on and is secured to a molded-in hook formation on the reservoir body, behind the filler neck. The reservoir also has a provision for a washer fluid level sensor. The washer reservoir, grommet seals and filler cap are each available for service. Rear The rear window washer fluid reservoir is secured to the inside of the lower right liftgate opening pillar in the rear of the passenger compartment. The washer pump and motor unit has a barbed nipple, which is installed through a rubber grommet seal inserted in a hole near the bottom of the reservoir. The washer pump is retained by an interference fit between the barbed nipple and the grommet seal, which is a light press fit. The washer reservoir has a remote fill cup with a snap-fit filler cap located on the right outer liftgate opening pillar drain channel. A molded rubber filler tube and a vent hose are routed from nipples on the fill cup through a hole in the liftgate opening pillar and are retained to nipples molded into the reservoir by an interference fit. The vent hose allows the reservoir to be completely filled without washer fluid spit-back. The washer reservoir, the grommet seal, and the fill cup (which includes the filler cap, filler tube and vent hose) are each available for service. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Rear Washer Reservoir Fill Cup Windshield Washer Reservoir: Service and Repair Rear Washer Reservoir Fill Cup REMOVAL AND INSTALLATION 1. Remove the washer reservoir from the passenger compartment. 2. Securely tie a suitable length of cord or twine to the washer reservoir end of the vent hose. This cord is to be used to "fish" the vent hose back through the right liftgate opening pillar during reinstallation. If this method is not used, the right outboard seat belt retractor assembly for the third seat (if the vehicle is so equipped) may have to be removed in order to properly route the vent hose through the pillar. 3. Pull the fill cup away from the right liftgate opening pillar drain channel to unseat it. 4. Remove the fill cup, fill hose and vent hose from the pillar as a unit. 5. Reverse the removal procedures to install. Be certain that the fill hose and vent hose are connected to the reservoir before seating the fill cup to the pillar. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Rear Washer Reservoir Fill Cup > Page 7290 Windshield Washer Reservoir: Service and Repair Washer Reservoir REMOVAL AND INSTALLATION Front 1. Disconnect and isolate the battery negative cable. 2. Remove the engine air filter housing. Front Washer System 3. Remove the screw that secures the reservoir to the inner fender shield. 4. Remove the two screws that secure the reservoir to the cowl plenum panel. 5. Move the reservoir far enough to access the washer pump. 6. Unplug the wire harness connectors from the washer pump and the washer fluid level sensor. 7. Remove the washer supply hose from the washer pump and drain the washer fluid from the reservoir into a clean container for reuse. 8. Remove the reservoir from the engine compartment. 9. Reverse the removal procedures to install. Tighten the reservoir mounting screws to 2.7 Nm (24 in. lbs.). Rear 1. Disconnect and isolate the battery negative cable. 2. Remove the right quarter trim panel from the interior of the vehicle. 3. Disconnect the washer supply hose from the check valve located on the inside surface of the right liftgate opening pillar near the liftgate opening header. 4. Disengage the washer supply hose from the retainers on the right liftgate opening pillar. Use the supply hose to siphon the washer fluid from the reservoir through the washer pump and into a clean container for reuse. 5. Remove the washer supply hose from the washer pump. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Rear Washer Reservoir Fill Cup > Page 7291 Rear Washer Reservoir Remove/Install 6. Unplug the wire harness connector from the washer pump. 7. Disconnect the vent hose from the nipple on the top of the washer reservoir. 8. Remove the two screws that secure the reservoir to the quarter inner panel and the liftgate opening sill panel. 9. Pull the washer reservoir away from the right liftgate opening pillar far enough to access and disconnect the fill hose from the fill nipple on the reservoir. 10. Remove the reservoir from the passenger compartment. 11. Reverse the removal procedures to install. Tighten the reservoir mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation Windshield Washer Spray Nozzle: Description and Operation SYSTEM OPERATION Front Pressurized washer fluid is fed through a single hose, attached to a barbed nipple on the washer pump. The hose is routed through a grommet inserted in a hole in the cowl plenum panel to an inline fitting located in the cowl plenum area, beneath the cowl plenum cover/grille panel. A hose from the in-line fitting in the cowl plenum is routed through clips molded into the underside of the cowl plenum cover/grille panel to a way fitting near the passenger side washer nozzle. Hoses from the way fitting are routed to the two washer nozzles, which are snap-fit into openings in the cowl plenum cover/grille panel. The two fluidic washer nozzles are not adjustable. The nozzles and hose fittings cannot be repaired and, if faulty or damaged, they must be replaced. Rear Pressurized washer fluid is fed through a single hose, attached to a barbed nipple on the rear window washer pump. The hose is routed from the reservoir up the right liftgate opening pillar to the liftgate opening header with the body wire harness. Located near the top of the supply hose routing, beneath the right liftgate opening pillar trim, the hose connects to a check valve. The check valve prevents washer fluid drain-back or siphoning from occurring. From the check valve, another single hose is routed to the liftgate opening header panel. There the hose passes through a grommet out of the liftgate opening header and through another grommet into the top of the liftgate inner panel. Within the lift- gate, the hose is connected to a nipple that protrudes from the fluidic washer nozzle, which is snap-fit into a keyed hole in the top of the liftgate outer panel. The rear window washer nozzle cannot be adjusted. The nozzle, check valve, and hose fittings cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Page 7295 Windshield Washer Spray Nozzle: Service and Repair REMOVAL AND INSTALLATION Front 1. Remove the cowl plenum cover/grille panel from the cowl top. See Wiper Motor/Service and Repair for the procedures. 2. From the underside of the cowl plenum cover/ grille panel, disconnect the washer hose from the nozzle fitting. 3. From the underside of the cowl plenum cover/ grille panel, compress the retaining tabs of the washer nozzle and push the nozzle out through the top of the panel. 4. Reverse the removal procedures to install. Rear 1. Using a trim stick or another suitable wide flat-bladed tool, pry gently at each side of the rear washer nozzle to release the snap clips that secure it to the liftgate outer panel. 2. Pull the nozzle out from the liftgate outer panel far enough to access and disconnect the washer supply hose from the nozzle nipple. 3. Reverse the removal procedures to install. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications Windshield Washer Switch: Specifications Wiper/Washer Mounting Screws 20 in.lb Multi-Function Switch Wiring Harness Connector Screw 17 in.lb Multi-Function Switch Mounting Screws (2) 17 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7299 Windshield Washer Switch: Locations The windshield wiper and washer switches are contained in the multi-function switch assembly which is secured to the left side of the steering column. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7300 Multi-Function Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7301 Windshield Washer Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AN AIR-BAG, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7302 Windshield Washer Switch: Description and Operation SYSTEM OPERATION Front Multi-Function Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay, or depressed toward the steering column to activate the washer system. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained in this addresses only the switch functions for the windshield wiper and washer systems. For information relative to the other switch functions. However, the multi-function switch cannot be repaired. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Rear The single two-function rear wiper and washer switch is integral to the rear window switch pod, which includes the rear window defogger switch. The rear window switch pod is installed in the instrument panel lower bezel, which is located near the center of the lower instrument panel, below the heater and air conditioner controls. The rear wiper and washer switch controls the rear wiper and washer functions. The rear window switch pod 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 sliding-type switch features a detent in the On position for the rear wiper. Pushing in on the rear wiper switch button activates the momentary rear washer switch. The rear wiper and washer switch also has an integral illumination lamp with a serviceable bulb. Both the rear wiper and rear washer motors will operate continuously for as long as the switch is held in the momentary Wash position. The rear wiper and washer switch cannot be repaired and, if faulty or damaged, the entire rear window switch pod must be replaced. Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module and an illuminated entry module into a single unit. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD 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 Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7303 allows the addition of many new feature capabilities. Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-afterwash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermittent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. Refer to Central Timer module/Service and Repair of Instrument Panel Systems for the service procedures. See Wiper System Testing and Inspection for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7304 Windshield Washer Switch: Testing and Inspection Front See Wiper System and/or Washer System Testing and Inspection before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AN AIR-BAG, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. Unplug the multi-function switch wire harness connector from the multi-function switch. Multi-Function Switch Continuity 3. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 4. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required. Rear Perform the diagnosis for the rear wiper system and/or washer system as described before testing the rear wiper and washer switch. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the lower bezel from the instrument panel and unplug the rear window switch pod wire harness connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7305 Rear Wiper Switch And Washer Switch Continuity 2. Using an ohmmeter, check the rear wiper and washer switch continuity at the rear window switch pod terminals as shown in the Rear Wiper Switch and Washer Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty rear window switch pod. If the switch is OK, repair the rear wiper system and/or washer system wire harness circuits as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7306 Windshield Washer Switch: Service and Repair REMOVAL AND INSTALLATION Front WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multifunction Switch 5. Move the upper fixed column shroud far enough to access the rear of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the switch away from the steering column far enough to access and remove the multifunction switch wire harness connector screw. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: Multi-function switch wire harness connector screw -2 Nm (17 in. lbs.) - Multi-function switch mounting screws - 2 Nm (17 in. lbs.). Rear Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7307 WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. 2. Remove the lower bezel from the instrument panel. Refer to Instrument Panel Lower Bezel/Service and Repair of Instrument Panel Systems for the procedures. Rear Window Switch Pod Remove/Install 3. Remove the two screws that secure the rear window switch pod to the instrument panel lower bezel. 4. Remove the rear window switch pod from the instrument panel lower bezel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications Wiper Arm: Specifications Wiper Arm Pivot Nuts 212 in.lb Wiper Arm to Rear Wiper Motor Output Shaft Mounting Nut 160 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 7311 Wiper Arm Remove/Install Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 7312 Wiper Arm: Description and Operation SYSTEM OPERATION All Durango models have two 50.8-centimeter (20-inch) windshield wiper blades with non-replaceable rubber elements (squeegees). These wiper blades include an anti-lift feature. The wiper blades and squeegees must be oriented correctly when installed on the wiper arms for the anti-lift feature to be effective. See Wiper Blade/Service and Repair for more information. The standard rear wiper uses a single 40.0-centimeter (15.75-inch) wiper blade with a non-replaceable rubber element (squeegee). Caution should be exercised to protect the rubber squeegees from any petroleum-based cleaners or contaminants, which will rapidly deteriorate the rubber. If the squeegees are damaged, worn, or contaminated, the entire wiper blade assembly must be replaced. Wiper squeegees exposed to the elements for a long time tend to lose their wiping effectiveness. Periodic cleaning of the squeegees is suggested to remove deposits of salt and road film. The wiper blades, arms, and windshield or rear glass should be cleaned with a sponge or cloth and windshield washer fluid, a mild detergent, or a non-abrasive cleaner. If the squeegees continue to streak or smear, the wiper blades should be replaced. The blades are mounted to spring-loaded wiper arms. The spring tension of the wiper arms controls the pressure applied to the blades on the glass. The windshield wiper arms are secured by a nut to each of the two wiper pivots on the cowl plenum cover/ grille panel at the base of the windshield. The rear wiper arm is secured by a nut directly to the rear wiper motor output shaft on the liftgate below the rear window glass. The wiper arms and blades cannot be adjusted or repaired. If faulty or damaged, they must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 7313 Wiper Arm: Service and Repair REMOVAL AND INSTALLATION CAUTION: The use of a screwdriver or other prying tool to remove a wiper arm may distort it. This distortion could allow the arm to come off of the pivot shaft, regardless of how carefully it is installed. Front 1. Open the hood of the vehicle. Wiper Arm Remove/Install 2. Unsnap the wiper arm pivot cover by lifting it at the pivot end of the arm. 3. Remove the pivot cover by pulling it straight out from where it snaps into the wiper arm hinge. 4. Remove the nut that secures the wiper arm to the wiper pivot. Wiper Arm Puller 5. Use a battery terminal puller to remove the wiper arm from the wiper pivot. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 7314 Wiper Arm Installation 6. Install the arm and blade with the wiper motor in the Park position. See the Wiper Arm Installation illustration. 7. Mount the arms on the pivot shafts so that the front and rear edges of the wiper blade are aligned with the wiper alignment lines concealed in the upper margin of the lower windshield blackout area, to ± 15 mm (± 0.59 in.). 8. Install the wiper arm pivot nuts and tighten to 24 Nm (212 in. lbs). 9. Operate the wipers with the windshield glass wet, then turn the wiper switch to the Off position. Check for the correct wiper arm positioning and readjust if required. 10. Snap the pivot covers back onto the wiper arms. Rear Fig.14 Rear Wiper Arm 1. Unsnap the rear wiper arm pivot cover by lifting it at the rear wiper motor output shaft end of the arm. 2. Remove the nut that secures the wiper arm to the rear wiper motor output shaft. 3. Use a battery terminal puller to remove the wiper arm from the wiper pivot. 4. Install the arm and blade with the rear wiper motor in the Park position. 5. Mount the wiper arm on the rear wiper motor output shaft so that the center of the wiper blade is aligned with the wiper alignment line concealed in the upper margin of the lower rear window blackout area. 6. Install the nut that secures the wiper arm to the rear wiper motor output shaft. Tighten the mounting nut to 18 Nm (160 in. lbs.). 7. Operate the rear wiper with the rear window glass wet, then turn the rear wiper switch to the Off position. Check for the correct wiper arm positioning and readjust if required. 8. Snap the pivot cover back over the rear wiper arm mounting nut. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 7328 Wiper Blade: Description and Operation SYSTEM OPERATION All Durango models have two 50.8-centimeter (20-inch) windshield wiper blades with non-replaceable rubber elements (squeegees). These wiper blades include an anti-lift feature. The wiper blades and squeegees must be oriented correctly when installed on the wiper arms for the anti-lift feature to be effective. See Wiper Blade/Service and Repair for more information. The standard rear wiper uses a single 40.0-centimeter (15.75-inch) wiper blade with a non-replaceable rubber element (squeegee). Caution should be exercised to protect the rubber squeegees from any petroleum-based cleaners or contaminants, which will rapidly deteriorate the rubber. If the squeegees are damaged, worn, or contaminated, the entire wiper blade assembly must be replaced. Wiper squeegees exposed to the elements for a long time tend to lose their wiping effectiveness. Periodic cleaning of the squeegees is suggested to remove deposits of salt and road film. The wiper blades, arms, and windshield or rear glass should be cleaned with a sponge or cloth and windshield washer fluid, a mild detergent, or a non-abrasive cleaner. If the squeegees continue to streak or smear, the wiper blades should be replaced. The blades are mounted to spring-loaded wiper arms. The spring tension of the wiper arms controls the pressure applied to the blades on the glass. The windshield wiper arms are secured by a nut to each of the two wiper pivots on the cowl plenum cover/ grille panel at the base of the windshield. The rear wiper arm is secured by a nut directly to the rear wiper motor output shaft on the liftgate below the rear window glass. The wiper arms and blades cannot be adjusted or repaired. If faulty or damaged, they must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 7329 Wiper Blade: Service and Repair REMOVAL AND INSTALLATION Front 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 pivot. 1. Turn the windshield wiper switch to the On position. By turning the ignition switch to the On and Off positions, cycle the wiper blades to a convenient working location on the windshield. 2. Lift the wiper arm to raise the wiper blade and element off of the windshield glass. Wiper Blade Remove/Install - Typical 3. To remove the wiper blade from the wiper arm, push the release tab under the arm tip and slide the blade away from the tip towards the pivot end of the arm. 4. To install the wiper blade on the wiper arm, slide the blade retainer into the U-shaped formation on the tip of the wiper arm until the release tab snaps into its locked position. Be certain that the notched retainer for the wiper element is oriented towards the end of the wiper blade that is nearest to the wiper pivot. Rear 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. 1. Lift the rear wiper arm to raise the wiper blade and element off of the rear window glass. 2. To remove the wiper blade from the wiper arm, push the release tab under the arm tip and slide the blade away from the tip towards the rear wiper motor output shaft end of the arm. 3. To install the wiper blade on the wiper arm, slide the blade retainer into the U-shaped formation on the tip of the wiper arm until the release tab snaps into its locked position. Be certain that the notched retainer for the wiper element is oriented towards the end of the wiper blade that is nearest to the rear wiper motor output shaft. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications Wiper Motor: Specifications Cowl Plenum Cover/Grille Panel Mounting Screws 72 in.lb Rear Wiper Motor Mounting Bracket Screws 72 in.lb Rear Wiper Motor Output Shaft Nut in Liftgate Outer Panel Mounting Hole 43 in.lb Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 7333 Wiper Motor Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 7334 Wiper Motor: Description and Operation SYSTEM OPERATION Front The two-speed permanent magnet wiper motor has an integral transmission and park switch. The motor also contains an internal automatic resetting circuit breaker to protect the motor from overloads. The motor is secured near the center of the tubular wiper linkage and pivot module bracket with three screws. 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. Wiper speed is controlled by current flow to the proper set of brushes. The wiper motor completes its wipe cycle when the windshield wiper switch on the end of the multi-function switch stalk is turned to the Off position, and parks the blades in the lowest portion of the wipe pattern. The windshield wiper linkage, pivots, bushings, mounting bracket, and motor are only serviced as a complete unit. If any part of this unit is faulty or damaged, the entire wiper module must be replaced. Rear The rear wiper motor is secured to a bracket that is fastened to the liftgate inner panel with two screws through two rubber grommet-type insulators, below the rear window glass and behind the liftgate trim panel. The motor output shaft passes through the liftgate outer panel where a rubber grommet and a nut seal and secure the unit to the liftgate outer panel. A plastic cover snaps onto the motor output shaft to conceal the mounting nut. The rear wiper arm is secured directly to the motor output shaft with another nut, which is also concealed by a plastic cover that snaps onto the end of the wiper arm. The rear wiper motor unit provides a single speed intermittent-cycle operating mode, which is provided by an electronic timer circuit that is integral to the motor unit. The rear wiper motor cannot be repaired. If faulty or damaged, the entire rear wiper motor assembly must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 7335 Wiper Motor: Service and Repair REMOVAL Front 1. Disconnect and isolate the battery negative cable. 2. Remove the wiper arms from the wiper pivots. Cowl Plenum Cover/Grille Panel Weatherstrip 3. Remove the weatherstrip along the front edge of the cowl plenum cover/grille panel and the cowl plenum panel. Cowl Plenum Cover/Grille Panel Remove/Install 4. Remove the four plastic nuts that secure the cowl plenum cover/grille panel to the studs on the cowl top panel near the base of the windshield. 5. Remove the one plastic rivet that secures the front corner on each side of the cowl plenum coven grille panel to the cowl plenum panel. 6. Remove the one plastic push-in retainer that secures the rear corner on each side of the cowl plenum cover/grille panel to the windshield reveal moulding. 7. Unsnap the slotted center hole on each side of the cowl plenum cover/grille panel from the adhesive- backed snap fastener. This fastener is secured to the top of each cowl side panel with an adhesive backing, and should not be removed during cowl plenum cover/grille panel removal. 8. Lift the cowl plenum cover/grille panel from the cowl top far enough to access the windshield washer nozzle and vacuum plumbing near the right end of the cowl plenum. 9. Disconnect the windshield washer supply hose at the in-line connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 7336 Vacuum Reservoir 10. Disconnect the vacuum supply hose from the vacuum reservoir, which is secured to the underside of the right end of the cowl plenum cover/grille panel. 11. Remove the cowl plenum cover/grille panel from the vehicle and set it aside. Wiper Module Remove/Install 12. Remove the four screws that secure the wiper module to the cowl plenum panel. 13. Move the wiper module as required to access the wiper motor wire harness connector. 14. Unplug the wiper motor wire harness connector from the wiper motor. 15. Remove the wiper module from the cowl plenum. 16. Reverse the removal procedures to install. Be certain that the washer nozzle hoses are correctly routed and installed in the retainers on the underside of the cowl plenum cover/grille panel. Tighten the mounting screws to 8 Nm (72 in. lbs.). Rear 1. Disconnect and isolate the battery negative cable. 2. From the outside of the liftgate, remove the rear wiper arm from the rear wiper motor output shaft. See Wiper Arm/Service and Repair for the procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 7337 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. Be certain to use proper caution to protect the outer liftgate panel and its paint finish from damage during this procedure. 4. Remove the nut that secures the rear wiper motor output shaft to the outer liftgate panel. 5. Pull the bezel and grommet off of the rear wiper motor output shaft. 6. Remove the liftgate trim panel from the lift-gate. 7. Unplug the rear wiper motor wire harness connector. 8. While supporting the wiper motor with a free hand, 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. 10. When reinstalling the rear wiper motor to the liftgate, first position the motor and bracket to the liftgate inner panel and secure it by loosely installing the mounting screws. 11. From the outside of the liftgate, 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 4.8 Nm (43 in. lbs.). 12. Reverse the remaining removal procedures to complete the installation. Tighten the rear wiper motor mounting bracket screws to 8.1 Nm (72 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Description and Operation Wiper Motor Linkage: Description and Operation SYSTEM OPERATION The wiper linkage and pivot module is secured with four screws through four rubber grommet-type insulators to the cowl plenum panel beneath the cowl plenum cover/grille panel. The wiper motor is secured with screws near the center of the tubular linkage and pivot module bracket, and the wiper pivots are secured to the ends of the module bracket. The two wiper pivot crank arms and the wiper motor crank arm each have ball studs on their ends. The motor crank arm ball stud is the longer of the three. Two drive links connect the motor crank arm to the pivot crank arms. The passenger side drive link has a plastic socket-type bushing on each end. The driver side drive link has a plastic socket-type bushing on one end, and a plastic sleeve-type bushing on the other end. The socket-type bushing on one end of each drive link is snap-fit over the ball stud on the crank arm of its respective pivot. The driver side drive link sleeve-type bushing end is then fit over the motor crank arm ball stud, and the second socket-type bushing of the passenger side drive link is snap-fit over the exposed end of the motor crank arm ball stud. The wiper linkage, pivots, bushings, mounting bracket, and motor are only serviced as a complete unit. If any part of this assembly is faulty or damaged, the entire wiper module must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Description and Operation > Page 7341 Wiper Motor Linkage: Service and Repair REMOVAL AND INSTALLATION The wiper linkage and pivots can only be removed from or installed in the vehicle as a unit with the wiper motor. See Wiper Motor/Service and Repair for the procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Description and Operation Wiper Pivot: Description and Operation SYSTEM OPERATION The wiper linkage and pivot module is secured with four screws through four rubber grommet-type insulators to the cowl plenum panel beneath the cowl plenum cover/grille panel. The wiper motor is secured with screws near the center of the tubular linkage and pivot module bracket, and the wiper pivots are secured to the ends of the module bracket. The two wiper pivot crank arms and the wiper motor crank arm each have ball studs on their ends. The motor crank arm ball stud is the longer of the three. Two drive links connect the motor crank arm to the pivot crank arms. The passenger side drive link has a plastic socket-type bushing on each end. The driver side drive link has a plastic socket-type bushing on one end, and a plastic sleeve-type bushing on the other end. The socket-type bushing on one end of each drive link is snap-fit over the ball stud on the crank arm of its respective pivot. The driver side drive link sleeve-type bushing end is then fit over the motor crank arm ball stud, and the second socket-type bushing of the passenger side drive link is snap-fit over the exposed end of the motor crank arm ball stud. The wiper linkage, pivots, bushings, mounting bracket, and motor are only serviced as a complete unit. If any part of this assembly is faulty or damaged, the entire wiper module must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Description and Operation > Page 7345 Wiper Pivot: Service and Repair REMOVAL AND INSTALLATION The wiper linkage and pivots can only be removed from or installed in the vehicle as a unit with the wiper motor. See Wiper Motor/Service and Repair for the procedures. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Power Distribution Center The intermittent wipe relay is located in the Power Distribution Center (PDC), in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7349 Wiper Relay: Diagrams Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7350 Wiper Relay Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7351 Wiper Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN,OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7352 Wiper Relay: Description and Operation SYSTEM OPERATION The intermittent wipe relay is a 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The intermittent wipe relay is a electromechanical device that switches battery current to the windshield wiper motor or wiper motor park switch when the relay coil is grounded by the Central Timer Module (CTM) in response to inputs from the windshield wiper (multi-function) switch. See Testing and Inspection. The intermittent wipe relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. The intermittent wipe relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7353 Wiper Relay: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN,OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Relay Test Intermittent Wipe Relay The intermittent wipe relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for intermittent wipe relay identification and location. Remove the intermittent wipe relay from the PDC as described in the Service and Repair 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 Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the wiper (multi-function) switch. There should be continuity between the cavity for relay terminal 30 and the two fused ignition switch output circuit cavities of the multi-function switch wire harness connector at all times. If OK, go to Step 2. If not OK, repair the open circuit(s) to the multi-function switch as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position. There should be continuity between the cavity for relay terminal 87A and the wiper park switch sense circuit cavities of the wiper motor wire harness connector and the 14-way Central Timer Module (CTM) wire harness connector at all times. If OK, go to Step 3. If not OK, repair the open circuit(s) to the wiper motor and CTM as required. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. There should be battery voltage at the cavity for relay terminal 87 with the ignition switch in the On or Accessory positions. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the On or Accessory positions. If OK, go to Step 5. If not OK, repair the open circuit to the ignition switch as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay It is grounded by the CTM to energize the relay and cycle the wiper motor. Check for continuity between the cavity for relay terminal 85 and the intermittent wiper relay control circuit cavity of the 14-way CTM wire harness connector. There should be continuity. If OK, replace the faulty base version CTM; or, use a DRB scan tool and the proper Diagnostic Procedures for diagnosis of the high-line version CTM. If not OK, repair the open circuit to the CTM as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7354 Wiper Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC cover for intermittent wipe relay identification and location. 4. Unplug the intermittent wipe relay from the PDC. 5. Install the intermittent wipe relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Specifications Wiper Switch: Specifications Tighten the fasteners as follows: Multi-function switch wire harness connector screw 2 Nm (17 in. lbs.) Multi-function switch mounting screws 2 Nm (17 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 7358 Wiper Switch: Locations The windshield wiper and washer switches are contained in the multi-function switch assembly which is secured to the left side of the steering column. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 7359 Multi-Function Switch Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 7360 Wiper Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AN AIR-BAG, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 7361 Wiper Switch: Description and Operation SYSTEM OPERATION Front Multi-Function Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay, or depressed toward the steering column to activate the washer system. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information addresses only the switch functions for the windshield wiper and washer systems. However, the multi-function switch cannot be repaired. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Rear The single two-function rear wiper and washer switch is integral to the rear window switch pod, which includes the rear window defogger switch. The rear window switch pod is installed in the instrument panel lower bezel, which is located near the center of the lower instrument panel, below the heater and air conditioner controls. The rear wiper and washer switch controls the rear wiper and washer functions. The rear window switch pod 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 sliding-type switch features a detent in the On position for the rear wiper. Pushing in on the rear wiper switch button activates the momentary rear washer switch. The rear wiper and washer switch also has an integral illumination lamp with a serviceable bulb. Both the rear wiper and rear washer motors will operate continuously for as long as the switch is held in the momentary Wash position. The rear wiper and washer switch cannot be repaired and, if faulty or damaged, the entire rear window switch pod must be replaced. Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module and an illuminated entry module into a single unit. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD 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. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 7362 Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-afterwash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermittent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. Refer to Central Timer Module/Service and Repair of Instrument Panel Systems for the service procedures. See Wiper System Testing and Inspection for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 7363 Wiper Switch: Testing and Inspection Front See Wiper System and/or Washer System Testing and Inspection before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AN AIR-BAG, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS 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. Unplug the multi-function switch wire harness connector from the multi-function switch. Multi-Function Switch Continuity 3. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 4. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required. Rear Perform the diagnosis for the rear wiper system and/or washer system as described before testing the rear wiper and washer switch. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the lower bezel from the instrument panel and unplug the rear window switch pod wire harness connector. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 7364 Rear Wiper Switch And Washer Switch Continuity 2. Using an ohmmeter, check the rear wiper and washer switch continuity at the rear window switch pod terminals as shown in the Rear Wiper Switch and Washer Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty rear window switch pod. If the switch is OK, repair the rear wiper system and/or washer system wire harness circuits as required. Dodge Durango 4wd Workshop Manual (V8-5.9L VIN Z LDC (1999)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 7365 Wiper Switch: Service and Repair REMOVAL AND INSTALLATION Front WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multifunction Switch 5. Move the upper fixed column shroud far enough to access the rear of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the switch away from the steering column far enough to access and remove the multifunction switch wire harness connector screw. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: a. Multi-function switch wire harness connector screw - 2 Nm (17 in. lbs.) b. Multi-function switch mounting screws - 2 Nm (17 in. lbs.). Rear